Shingled array solar cells and method of manufacturing solar modules including the same

ABSTRACT

A solar cell is provided including a substrate having a front and back side, a metallization pattern deposited on the front side, the metallization pattern including a plurality of front side bus bars each including fingers extending therefrom, and a plurality of back side bus bars deposited on the back side. On the front side, one front side bus bar is formed along an edge of the front side of the substrate, and a remainder of the front side bus bars are unequally spaced across the substrate. On the back side of the substrate, only one back side bus bar is formed along an edge of the back side of the substrate, and a remainder of the back side bus bars are unequally spaced across the substrate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/794,699, filed Oct. 26, 2017, now U.S. Pat. No. 9,935,222, which is acontinuation of U.S. patent application Ser. No. 15/622,783, filed onJun. 14, 2017, now U.S. Pat. No. 9,935,221, which is a continuation ofPCT/CN17/76017, filed Mar. 9, 2017, the entire contents of each of whichare incorporated by reference herein.

TECHNICAL FIELD

The present disclosure relates to solar modules, and more particularly,to solar cells incorporated into shingled array module (“SAM”), whichdeliver a much higher module efficiency than conventional ribboninterconnected modules.

BACKGROUND

Over the past few years, the use of fossil fuels as an energy source hasbeen trending downward. Many factors have contributed to this trend. Forexample, it has long been recognized that the use of fossil fuel-basedenergy options, such as oil, coal, and natural gas, produces gases andpollution may not be easily removed from the atmosphere. Additionally,as more fossil fuel-based energy is consumed, the more pollution isdischarged into the atmosphere causing harmful effects on life close by.Despite these effects, fossil-fuel based energy options still are beingdepleted at a rapid pace, and as a result, the costs of some of thesefossil fuel resources, such as oil, have risen. Further, as many of thefossil fuel reserves are located in politically unstable areas, thesupply and costs of fossil fuels have been unpredictable.

Due in part to the many challenges presented by these traditional energysources, the demand for alternative, clean energy sources has increaseddramatically. To further encourage solar energy and other clean energyusage, some governments have provided incentives, in the form ofmonetary rebates or tax relief, consumers willing to switch fromtraditional energy sources to clean energy sources. In other instances,consumers have found that the long-term savings benefits of changing toclean energy sources have outweighed the relatively high upfront cost ofimplementing clean energy sources.

One form of clean energy, solar energy, has risen in popularity over thepast few years. Advancements in semiconductor technology have allowedthe designs of solar modules and solar panels to be more efficient andcapable of greater output. Further, the materials for manufacturingsolar modules and solar panels have become relatively inexpensive, whichhas contributed to the decrease in costs of solar energy. As solarenergy has increasingly become an affordable clean energy option forindividual consumers, solar module and panel manufacturers have madeavailable products with aesthetic and utilitarian appeal forimplementation on residential structures. As a result of these benefits,solar energy has gained widespread global popularity.

SUMMARY

Although solar module designs have made many advancements over the pastfew years, they may be improved. For example, solar cells from which thesolar modules are manufactured are still using the symmetricalmetallization patterns on front and rear surfaces per ribbon solderinginterconnection requirements. Additionally, the manufacturing processesthemselves can be optimized further to reduce optical and resistivelosses.

The present disclosure addresses the aforementioned shortcomings. In anaspect of the present disclosure, a solar cell is provided that includesa substrate having a front side and a back side, a metallization patterndeposited on the front side of the substrate, the metallization patternincluding a plurality of front side bus bars, each front side bus barincluding fingers extending therefrom, and a plurality of back side busbars deposited on the back side of the substrate. On the front side ofthe substrate, one front side bus bar of the plurality of front side busbars is formed along an edge of the front side of the substrate, and aremainder of the front side bus bars of the plurality of front side busbars are unequally spaced across the substrate. On the back side of thesubstrate, only one back side bus bar of the plurality of back side busbars is formed along an edge of the back side of the substrate, and aremainder of the back side bus bars of the plurality of back side busbars are unequally spaced across the substrate.

In another aspect of the present disclosure, the remainder of the frontside bus bars of the plurality of front side bus bars include two frontside bus bars that are adjacent each other.

In another aspect of the present disclosure, each front side bus bar ofthe plurality of front side bus bars includes finger lines extendingtherefrom and two sets of the finger lines point towards each other. Instill another aspect of the present disclosure, one of the two sets offinger lines extends from the one front side bus bar formed along theedge of the front side of the substrate. Alternatively, in an aspect ofthe present disclosure, neither of the two sets of finger lines extendsfrom the one front side bus bar formed along the edge of the front sideof the substrate.

In another aspect of the present disclosure, each front side bus bar ofthe plurality of front side bus bars includes finger lines extendingtherefrom, a first set of the finger lines point toward each other, anda second set of the finger lines point toward each other.

In another aspect of the present disclosure, the solar cell includesfive discrete sections, each section including one front side bus barand one back side bus bar.

In another aspect of the present disclosure, the solar cell includes sixdiscrete sections, each section including one front side bus bar and oneback side bus bar.

In another aspect of the present disclosure, the solar cell is dividableinto a plurality of strips, each strip is of substantially equal width,and each strip has a front side bus bar on an edge opposite from an edgeon which a back side bus bar is formed.

In another aspect of the present disclosure, the solar cell is dividableinto a plurality of strips, each strip is of substantially equal area,and each strip has a front side bus bar on an edge opposite from an edgeon which a back side bus bar is formed.

In accordance with another aspect of the present disclosure, a method isprovided of forming a solar cell. The method includes depositing ametallization pattern on a front side of a substrate, the metallizationpattern including a plurality of front side bus bars, each front sidebus bar including fingers extending therefrom, and depositing aplurality of back side bus bars on a back side of the substrate. On thefront side of the substrate, one front side bus bar of the plurality offront side bus bars is formed along an edge of the front side of thesubstrate, and a remainder of the front side bus bars of the pluralityof front side bus bars are unequally spaced across the substrate. On theback side of the substrate, only one back side bus bar of the pluralityof back side bus bars is formed along an edge of the back side of thesubstrate, and a remainder of the back side bus bars of the plurality ofback side bus bars are unequally spaced across the substrate.

In another aspect of the present disclosure, the remainder of the frontside bus bars of the plurality of front side bus bars include two frontside bus bars that are adjacent each other.

In another aspect of the present disclosure, each front side bus bar ofthe plurality of front side bus bars includes finger lines extendingtherefrom and two sets of the finger lines point towards each other. Instill another aspect of the present disclosure, one of the two sets offinger lines extends from the one front side bus bar formed along theedge of the front side of the substrate. In still yet another aspect ofthe present disclosure, neither of the two sets of finger lines extendsfrom the one front side bus bar formed along the edge of the front sideof the substrate.

In another aspect of the present disclosure, each front side bus bar ofthe plurality of front side bus bars includes finger lines extendingtherefrom, a first set of the finger lines point toward each other, anda second set of the finger lines point toward each other.

In another aspect of the present disclosure, the method also includesforming scribe lines into the solar cell to define five discretesections, each section including one front side bus bar and one backside bus bar.

In another aspect of the present disclosure, the method also includesforming scribe lines into the solar cell to define six discretesections, each section including one front side bus bar and one backside bus bar.

In another aspect of the present disclosure, the solar cell is dividableinto a plurality of strips, each strip is of substantially equal width,and each strip has a front side bus bar on an edge opposite from an edgeon which a back side bus bar is formed.

In another aspect of the present disclosure, the solar cell is dividableinto a plurality of strips, each strip is of substantially equal area,and each strip has a front side bus bar on an edge opposite from an edgeon which a back side bus bar is formed.

According to still yet another aspect of the present disclosure, a solarcell is provided including a substrate having a front side and a backside, a metallization pattern deposited on the front side of thesubstrate, the metallization pattern including a plurality of front sidebus bars, each front side bus bar including fingers extending therefrom,and a plurality of back side bus bars deposited on the back side of thesubstrate. On the front side of the substrate, no front side bus bar ofthe plurality of front side bus bars is formed along an edge of thefront side of the substrate, and the plurality of front side bus barsare unequally spaced across the substrate. On the back side of thesubstrate, two back side bus bars of the plurality of back side bus barsare each formed along a corresponding edge of the back side of thesubstrate, and a remainder of the back side bus bars of the plurality ofback side bus bars are unequally spaced across the substrate.

In another aspect of the present disclosure, the remainder of the frontside bus bars of the plurality of front side bus bars include two frontside bus bars that are adjacent each other.

In another aspect of the present disclosure, each front side bus bar ofthe plurality of front side bus bars includes finger lines extendingtherefrom and two sets of the finger lines point towards each other. Instill another aspect of the present disclosure, one of the two sets offinger lines extends from the one front side bus bar formed along theedge of the front side of the substrate. In still another aspect of thepresent disclosure, neither of the two sets of finger lines extends fromthe one front side bus bar formed along the edge of the front side ofthe substrate.

In another aspect of the present disclosure, each front side bus bar ofthe plurality of front side bus bars includes finger lines extendingtherefrom, a first set of the finger lines point toward each other, anda second set of the finger lines point toward each other.

In another aspect of the present disclosure, the solar cell includesfive discrete sections, each section including one front side bus barand one back side bus bar.

In another aspect of the present disclosure, the solar cell includes sixdiscrete sections, each section including one front side bus bar and oneback side bus bar.

In another aspect of the present disclosure, the solar cell is dividableinto a plurality of strips, each strip is of substantially equal width,and each strip has a front side bus bar on an edge opposite from an edgeon which a back side bus bar is formed.

In another aspect of the present disclosure, the solar cell is dividableinto a plurality of strips, each strip is of substantially equal area,and each strip has a front side bus bar on an edge opposite from an edgeon which a back side bus bar is formed.

According to still yet another aspect of the present disclosure, amethod of forming a solar cell is provided. The method includesdepositing a metallization pattern on the front side of the substrate,the metallization pattern including a plurality of front side bus bars,each front side bus bar including fingers extending therefrom, anddepositing a plurality of back side bus bars on the back side of thesubstrate. On the front side of the substrate, no front side bus bar ofthe plurality of front side bus bars is formed along an edge of thefront side of the substrate, and the plurality of front side bus barsare unevenly spaced apart from each other across the substrate. On theback side of the substrate, two back side bus bars of the plurality ofback side bus bars are each formed along a corresponding edge of theback side of the substrate, and a remainder of the back side bus bars ofthe plurality of back side bus bars are unequally spaced across thesubstrate.

In another aspect of the present disclosure, the remainder of the frontside bus bars of the plurality of front side bus bars include two frontside bus bars that are adjacent each other.

In another aspect of the present disclosure, each front side bus bar ofthe plurality of front side bus bars includes finger lines extendingtherefrom and two sets of the finger lines point towards each other.According to another aspect of the present disclosure, one of the twosets of finger lines extends from the one front side bus bar formedalong the edge of the front side of the substrate. According to stillanother aspect of the present disclosure, neither of the two sets offinger lines extends from the one front side bus bar formed along theedge of the front side of the substrate.

In another aspect of the present disclosure, each front side bus bar ofthe plurality of front side bus bars includes finger lines extendingtherefrom, a first set of the finger lines point toward each other, anda second set of the finger lines point toward each other.

In another aspect of the present disclosure, the method also includesforming scribe lines into the solar cell to define five discretesections, each section including one front side bus bar and one backside bus bar.

In another aspect of the present disclosure, the method also includesforming scribe lines into the solar cell to define six discretesections, each section including one front side bus bar and one backside bus bar.

In another aspect of the present disclosure, upon cleaving the solarcell into a plurality of strips, each strip is of substantially equalwidth and each strip has a front side bus bar on an edge opposite froman edge on which a back side bus bar is formed.

In another aspect of the present disclosure, upon cleaving the solarcell into a plurality of strips, each strip is of substantially equalarea and each strip has a front side bus bar on an edge opposite from anedge on which a back side bus bar is formed.

Further details and aspects of exemplary embodiments of the presentdisclosure are described in more detail below with reference to theappended figures.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of the present disclosure are described hereinbelow withreference to the drawings, which are incorporated in and constitute apart of this specification, wherein:

FIG. 1 is a front side plan view of a solar cell, according to anembodiment;

FIG. 2 is a back side plan view of the solar cell of FIG. 1, accordingto an embodiment;

FIG. 3 is a close-up view of a portion of the solar cell of FIG. 1,according to an embodiment;

FIGS. 4-23 are simplified front side and back side views of five stripsolar cells, according to various embodiments;

FIGS. 24-77 are simplified front side and back side views of six stripsolar cells, according to various embodiments;

FIG. 78 is a flow diagram of a method of forming a string of solar cellstrips, according to an embodiment;

FIG. 79 is a back side view of a solar cell including scribe lines,according to an embodiment;

FIG. 80 is a simplified schematic of a step of the method depicted inFIG. 78 during which scribing of the solar cell is performed, inaccordance with an embodiment;

FIG. 81 is a front side view of the solar cell of FIG. 79 aftersingulation, according to an embodiment;

FIG. 82 is a simplified schematic of a step of the method depicted inFIG. 78 during which strips of the solar cell are formed into a string,according to an embodiment;

FIG. 83 is a front side view of a string of solar cell strips havingchamfered corners, according to an embodiment;

FIG. 84 is a front side view of a string of solar cell strips havingnon-chamfered corners including end connectors soldered or conductivelyconnected to bus bars on the first and last strips of each string,according to an embodiment;

FIGS. 85A-85C are front side views of a solar module, according tovarious embodiments;

FIG. 86A and 86B are back side views of the solar modules of FIGS.85A-85C, according to various embodiments;

FIG. 87 is a close-up view of a portion of the solar module of FIG. 85Abounded by circle A;

FIG. 88 is a plan view of an isolation strip included in the solarmodule of FIG. 85A, according to an embodiment;

FIG. 89 is an electrical schematic for a solar module, according to anembodiment;

FIG. 90 is an electrical schematic for a solar module, according toanother embodiment;

FIG. 91 is an electrical schematic for a solar module, according tostill another embodiment;

FIG. 92 is a flow diagram of a method of manufacturing a solar module,according to an embodiment;

FIG. 93 is a cross-section view of a solar module, according to anembodiment;

FIG. 94 is a top view of a ribbon configuration of a bus bar, inaccordance with an embodiment;

FIG. 95 is a close up view of a portion of the solar module in FIG. 85B,illustrating an isolation strip and associated electrical connections,according to an embodiment;

FIG. 96 is a cross section view of the solar module illustrated in FIG.95 taken along line B-B; and

FIG. 97 is a cross section view of the solar module illustrated in FIG.95 taken along line C-C.

DETAILED DESCRIPTION

Unique solar cell designs are included that, when incorporated intosolar modules, provide improved efficiency and energy output and reducecosts. The solar cell designs take advantage of special metallizationpatterns formed on the solar cells, which inherently allow lower leakagecurrent to thereby boost cell performance and permit a manufacturer toset up solar cell testing equipment to measure the efficiency ofshingled array solar cells more accurately. This testing setup can leadto reduced time and expense during manufacture. Additionally, methodsare provided during which singulation of the solar cell into stripsoccurs substantially simultaneously to further reduce manufacturingtimes. Solar modules are provided that incorporate the strips of thesolar cells.

As alluded to briefly above, solar cells are used as the building blockof solar modules. With reference to FIGS. 1-3, various views of a solarcell 100 are provided, according to an embodiment. The solar cell 100 ismade up of a substrate 101 configured to be capable of producing energyby converting light energy into electricity. Examples of suitablephotovoltaic material include, but are not limited to, those made frommulticrystalline or monocrystalline silicon wafers. These wafers may beprocessed through the major solar cell processing steps, which includewet or dry texturization, junction diffusion, silicate glass layerremoval and edge isolation, silicon nitride anti-reflection layercoating, front and back metallization including screen printing, andfiring. The wafers may be further processed through advanced solarprocessing steps, including adding rear passivation coating andselective patterning to thereby obtain a passivated emitter rear contact(PERC) solar cell, which has a higher efficiency than solar cells formedusing the standard process flow mentioned above. The solar cell 100 is ap-type monocrystalline cell, in an embodiment, but may be a p-typemulticrystalline or an n-type monocrystalline cell in other embodiments.Similar to the diffused junction solar cells described as above, otherhigh efficiency solar cells, including heterojunction solar cells, canutilize the same metallization patterns in order to be used for themanufacture of a shingled array module. The solar cell 100 may have asubstantially square shape with chamfered corners (a pseudo-square) or afull square shape. As illustrated in the figures, these options aredepicted with dashed lines showing the alternative configurations.

As illustrated in FIG. 1, the solar cell 100 has a metallization pattern102 formed on a front side 104 of the substrate 101. The metallizationpattern 102 generally includes a plurality of discrete sections 106,108, 110, 112, 114, each of which has a front side bus bar 116, 118,120, 122, 124 and lines 126, 128, 130, 132, 134. The discrete sections106, 108, 110, 112, 114 are patterned such that, as will be describedlater, each discrete section 106, 108, 110, 112, 114 can be separatedfrom the solar cell 100 to form a strip. As such, the sections 106, 108,110, 112, 114 may be separated by a gap, which serves as a portion ofthe solar cell 100 at which a break may be made. The width of the gap,if included, is in a range of about 0.2 mm to about 2.0 mm. Here, fivediscrete sections 106, 108, 110, 112, 114 are included to thereby formfive strips total. The front side bus bars 116, 118, 120, 122, 124 aresubstantially parallel to each other, and each extends along a length ofthe solar cell 100 without intersecting the top and bottom edges 135,137 of the solar cell 100. With particular reference to FIG. 3, thelines 126, 128, 130, 132, 134 of each discrete section 106, 108, 110,112, 114 include finger lines, for example, finger line 140, eachextending between the front side bus bars 116, 118, 120, 122, 124 andboundary lines, for example, boundary line 142. Connection lines may beincluded to extend between adjacent finger lines 140 in an embodiment.

A back side 146 of the solar cell 100 likewise includes metallization,as illustrated in FIG. 2. In an embodiment, the back side 146 includes aplurality of back side bus bars 148, 150, 152, 154, 156, the totalnumber of which is equal to the number of front side bus bars 116, 118,120, 122, 124. Each back side bus bar 148, 150, 152, 154, 156corresponds to a discrete section 106, 108, 110, 112, 114. In anembodiment, the location of each back side bus bar 148, 150, 152, 154,156 depends on the location of a corresponding front side bus bar 116,118, 120, 122, 124. Specifically, upon cleaving the solar cell 100 intoa plurality of strips, each strip has a front side bus bar 116, 118,120, 122, 124 on an edge opposite from an edge on which a back side busbar 148, 150, 152, 154, 156 is formed. Further, each back side bus bar148, 150, 152, 154, 156 is formed at location on the solar cell 100 thatis not directly below a corresponding boundary line 142.

The particular locations of the front and back side bus bars arestrategically selected. In particular, the front side bus bars areformed at locations that are away from one or both of the edges of thesolar cell 100, which thereby reduces side leakage and improves shuntresistance. As a result, high yield and improved low irradiationperformance are achieved. Furthermore, by grouping two of the front sidebus bars together so that they are adjacent each other, three sets ofprobes may be employed, rather than the typical five or six sets ofprobes, to contact bus bars during flash testing. The fewer number ofprobes used also reduces the shadow impact of the probes during thetesting to thereby improve the accuracy and consistency of cellefficiency test.

In this regard, in an embodiment shown in FIG. 1, the left-most discretesection 106 includes boundary line 142 formed along the left edge 136 ofthe solar cell 100, and hence, left edge 160 of discrete section 106,while front side bus bar 116 is formed along a right edge 162 ofdiscrete section 106 towards an interior portion of the solar cell 100.At the right edge 138 of the solar cell 100, a boundary line 178 isformed along the right edge 164, and hence, front side bus bar 124 isformed towards the interior portion of the solar cell 100 along anopposite (or left) edge 176 of the right-most discrete section 114. Theremainder of the front side bus bars 118, 120, 122 are formed along aright edge of corresponding discrete sections 108, 110, 112. As such,the front side bus bars 116, 118, 120, 122, 124 are unevenly spacedapart across the solar cell 100.

Similarly, the back side bus bars 148, 150, 152, 154, 156 are alsounevenly spaced apart across the solar cell 100. Specifically, the backside bus bars 148, 150, 152, 154, 156 are formed at locations on theback side 146 of the solar cell 100 such that upon cleaving the solarcell 100 into a plurality of strips made up of each of the discretesections 106, 108, 110, 112, 114, the front side bus bar 116, 118, 120,122, 124 of the strip is on an edge opposite from an edge on which aback side bus bar 148, 150, 152, 154, 156 is formed. For example,turning to FIG. 2, back side bus bar 148 is formed along the left edge136 of the solar cell 100 (and hence, left edge 160 of discrete section106), while back side bus bar 156 is formed along the right edge 138 ofthe solar cell 100. Back side bus bars 150, 152, 154 are formed along aleft edge of corresponding discrete sections 108, 110, 112.

FIGS. 4 and 5 are simplified front and back side views of a solar cell400, according to another embodiment. The solar cell 400 has discretesections 406, 408, 410, 412, 414 each patterned on the front side 404 ofthe solar cell 400 to include front side bus bars 416, 418, 420, 422,424 and on the back side 446 of the solar cell 400 to include back sidebus bar 448, 450, 452, 454, 456. Similar to solar cell 100, fivediscrete sections 406, 408, 410, 412, 414 are included to thereby formfive strips total. Additionally, the front side bus bars 416, 418, 420,422, 424 are substantially parallel to each other, and each extendsalong a length of the solar cell 400 without intersecting the edges 435,437 of the solar cell 400. Each front side bus bar 416, 418, 420, 422,424 has finger lines extending away therefrom. Also similar to solarcell 100, the left-most discrete section 406 includes a boundary line(not shown) formed along the left edge 436 of the solar cell 400 (leftedge 460 of discrete section 406), while front side bus bar 416 isformed along the right edge 462 of discrete section 406. Also similar tosolar cell 100, a boundary line 478 is formed along the right edge 438of the solar cell 400, and hence, front side bus bar 424 is formedtowards the interior portion of the solar cell 400 along an opposite (orleft) edge 476 of the right-most discrete section 414. In contrast tosolar cell 100, the remainder of the front side bus bars 418, 420, 422of solar cell 400 are spaced differently; for example, the remainder ofthe front side bus bars 418, 420, 422 are unevenly spaced between theother front side bus bars 416, 424. In particular, front side bus bar418 is formed along a left edge 464 of discrete section 408, wherein theleft edge 464 is adjacent the right edge 462 of discrete section 406.Front side bus bar 420 is formed along a right edge 470 of discretesection 410. Additionally, front side bus bar 422 is formed along aright edge 474 of discrete sections 412, which is adjacent front sidebus bar 424 at the left edge 476 of discrete section 414. As such, thefront side bus bars 416, 418, 420, 422, 424 are unevenly spaced apartacross the solar cell 400. Back side bus bars 448, 450, 452, 454, 456are formed at corresponding opposite edge locations on the back side 446of the solar cell 400, as shown in FIG. 5. It will be appreciated thatone or more of the edges (for example, those referred to in FIGS. 4-76)may or may not be depicted as visible lines, in some embodiments.

FIGS. 6 and 7 are simplified front and back side views of a solar cell600, according to another embodiment. The solar cell 600 has discretesections 606, 608, 610, 612, 614 each patterned on the front side 604 ofthe solar cell 600 to include front side bus bars 616, 618, 620, 622,624 and on the back side 646 of the solar cell 600 to include back sidebus bar 648, 650, 652, 654, 656. Similar to solar cells 100 and 400,five discrete 606, 608, 610, 612, 614 are included to thereby form fivestrips total. Additionally, the front side bus bars 616, 618, 620, 622,624 are substantially parallel to each other, and each extends along alength of the solar cell 600 without intersecting the edges 635of thesolar cell 600. Each front side bus bar 616, 618, 620, 622, 624 hasfinger lines extending away therefrom. Also similar to solar cells 100and 400, the left-most discrete section 606 includes a boundary lineformed along the left edge 636 of the solar cell 600 (left edge 660 ofdiscrete section 606), while front side bus bar 616 is formed along theright edge 662 of discrete section 606. Also similar to solar cells 100and 400, a boundary line is formed along the right edge 638 of the solarcell 600, and hence, front side bus bar 624 is formed towards theinterior portion of the solar cell 600 along an opposite (or left) edge676 of the right-most discrete section 614.

The remainder of the front side bus bars 618, 620, 622 are unevenlyspaced between the other front side bus bars 616, 624. In particular,front side bus bar 618 is formed along a right edge 666 of discretesection 608, and adjacent right edge 666 is formed front side bus bar620 along a left edge 668 of discrete section 610. Front side bus bar622 is formed along a right edge 674 of discrete section 612.Accordingly, the front side bus bars 616, 618, 620, 622, 624 areunevenly spaced apart across the solar cell 600. Back side bus bars 648,650, 652, 654, 656 are formed at corresponding opposite edge locationson the back side 646 of the solar cell 600, as shown in FIG. 7.

FIGS. 8 and 9 are simplified front and back side views of a solar cell800, according to yet another embodiment. The solar cell 800 hasdiscrete sections 806, 808, 810, 812, 814 each patterned on the frontside 804 of the solar cell 800 to include front side bus bars 816, 818,820, 822, 824 and on the back side 846 of the solar cell 800 to includeback side bus bars 848, 850, 852, 854, 856. Similar to solar cells 100,400, and 600, five discrete sections 806, 808, 810, 812, 814 areincluded to thereby form five strips total, and the front side bus bars816, 818, 820, 822, 824 are substantially parallel to each other, andeach extends along a length of the solar cell 800 without intersectingthe edges 835of the solar cell 800. Each front side bus bar 816, 818,820, 822, 824 has finger lines extending away therefrom. Also similar tosolar cells 100, 400, and 600, a boundary line (not shown) formed onleft edge 836 of the solar cell 800, and front side bus bar 816 isformed also right edge 862 of discrete section 806, respectively, andfront side bus bar 824 and a boundary line are formed along left edge876 of discrete section 814 and right edge 838 of the solar cell 800,respectively.

The remainder of the front side bus bars 818, 820, 822 are also unevenlyspaced between the other front side bus bars 816, 824. In particular,front side bus bar 818 is formed along a right edge 866 of discretesection 808, front side bus bar 820 is formed along a right edge 870 ofdiscrete sections 810, and front side bus bar 822 is formed along theleft edge 872 of discrete section 812. Back side bus bars 848, 850, 852,854, 856 are formed at corresponding opposite edge locations on the backside 846 of the solar cell 800, as shown in FIG. 9.

In another embodiment, rather than having no bus bars formed along theedges of a solar cell, one bus bar is included. For example, asillustrated in FIGS. 10 and 11, The solar cell 1000 has discretesections 1006, 1008, 1010, 1012, 1014 each patterned on the front side1004 of the solar cell 1000 to include front side bus bars 1016, 1018,1020, 1022, 1024 and on the back side 1046 of the solar cell 1000 toinclude back side bus bars 1048, 1050, 1052, 1054, 1056. Five discretesections 1006, 1008, 1010, 1012, 1014 are included to thereby form fivestrips total, and the front side bus bars 1016, 1018, 1020, 1022, 1024are substantially parallel to each other, and each extends along alength of the solar cell 1000 without intersecting the edges 1035, 1037,1039 of the solar cell 1000. Each front side bus bar 1016, 1018, 1020,1022, 1024 has finger lines extending away therefrom. A boundary lineand front side bus bar 1016 are formed on left edge 1036 of the solarcell 1000 and right edge 1062 of discrete section 1006, respectively,while a boundary line and front side bus bar 1024 and are formed alongleft edge 1076 of discrete section 1014 and right edge 1038 of the solarcell 1000, respectively.

The remainder of the front side bus bars 1018, 1020, 1022 here areunevenly spaced between the other front side bus bars 1016, 1024 in amanner similar to front side bus bars 816, 818, 820, 822, 824 of thesolar cell 800 shown and described in FIGS. 8 and 9. Back side busbars1048, 1050, 1052, 1054, 1056 are formed at corresponding oppositeedge locations on the back side 1046 of the solar cell 1000, as shown inFIG. 11.

In another exemplary embodiment, as illustrated in FIGS. 12 and 13, thesolar cell 1200 here has discrete sections 1206, 1208, 1210, 1212, 1214each patterned on the front side 1204 of the solar cell 1200 to includefront side bus bars 1216, 1218, 1220, 1222, 1224 and on the back side1246 of the solar cell 1200 to include back side bus bars 1248, 1250,1252, 1254, 1256. Front side bus bars 1216, 1224 are formed at locationson the solar cell 1200 similar to those of front side bus bars 1016,1024, and the remainder of the front side bus bars 1218, 1220, 1222 hereare unevenly spaced between the other front side bus bars 1216, 1224 ina manner similar to front side bus bars 618, 620, 622 of solar cell 600.Each front side bus bar 1216, 1218, 1220, 1222, 1224 has finger linesextending away therefrom. Back side bus bars 1248, 1250, 1252, 1254,1256 are formed at corresponding opposite edge locations on the backside 1246 of the solar cell 1200, as shown in FIG. 13.

According to still another exemplary embodiment, as illustrated in FIGS.14 and 15, the solar cell 1400 here has discrete sections 1406, 1408,1410, 1412, 1414 each patterned on the front side 1404 of the solar cell1400 to include front side bus bars 1416, 1418, 1420, 1422, 1424 and onthe back side 1446 of the solar cell 1400 to include back side bus bars1448, 1450, 1452, 1454, 1456. Front side bus bars 1416, 1424 are formedat locations on the solar cell 1400 similar to those of front side busbars 1016, 1024 of solar cell 1000, and the remainder of the front sidebus bars 1418, 1420, 1422 here are unevenly spaced between the otherfront side bus bars 1416, 1424 in a manner similar to front side busbars 418, 420, 422 of solar cell 400. Back side bus bars 1448, 1450,1452, 1454, 1456 are formed at corresponding opposite edge locations onthe back side 1446 of the solar cell 1400, as shown in FIG. 15. Eachfront side bus bar 1416, 1418, 1420, 1422, 1424 has finger linesextending away therefrom.

According to still yet another exemplary embodiment, as illustrated inFIGS. 16 and 17, the solar cell 1600 here has discrete sections 1606,1608, 1610, 1612, 1614 each patterned on the front side 1604 of thesolar cell 1600 to include front side bus bars 1616, 1618, 1620, 1622,1624 and on the back side 1646 of the solar cell 1600 to include backside bus bars 1648, 1650, 1652, 1654, 1656. Front side bus bars 1616,1624 are formed at locations on the solar cell 1600 similar to those offront side bus bars 1016, 1024 of solar cell 1000. The remainder of thefront side bus bars 1618, 1620, 1622 here are unevenly spaced betweenthe other front side bus bars 1616, 1624. Specifically, front side busbar 1618 is formed along a right edge 1666 of discrete section 1608, andfront side bus bar 1620 extends along a left edge 1668 of discretesection 1610. Front side bus bar 1622 is formed along left edge 1672 ofdiscrete section 1612. Each front side bus bar 1616, 1618, 1620, 1622,1624 has finger lines extending away therefrom. Back side bus bars1648,1650, 1652, 1654, 1656 are formed at corresponding opposite edgelocations on the back side 1646 of the solar cell 1600, as shown in FIG.17.

In still yet another exemplary embodiment, as illustrated in FIGS. 18and 19, the solar cell 1800 here has discrete sections 1806, 1808, 1810,1812, 1814 each patterned on the front side 1804 of the solar cell 1800to include front side bus bars 1816, 1818, 1820, 1822, 1824 and on theback side 1846 of the solar cell 1800 to include back side bus bars1848, 1850, 1852, 1854, 1856. Front side bus bars 1816, 1824 are formedat locations on the solar cell 1800 similar to those of front side busbars 1016, 1024 of solar cell 1000. The remainder of the front side busbars 1818, 1820, 1822 here are unevenly spaced between the other frontside bus bars 1816, 1824. In particular, front side bus bar 1818 isformed along left edge 1864 of discrete section 1808, front side bus bar1820 is formed along right edge 1870 of discrete section 1810, and frontside bus bar 1822 is formed along left edge 1872 of discrete section1812. Each front side bus bar 1816, 1818, 1820, 1822, 1824 has fingerlines extending away therefrom. Back side bus bars 1848, 1850, 1852,1854, 1856 are formed at corresponding opposite edge locations on theback side 1846 of the solar cell 1800, as shown in FIG. 19.

In another exemplary embodiment, as illustrated in FIGS. 20 and 21, thesolar cell 2000 here has discrete sections 2006, 2008, 2010, 2012, 2014each patterned on the front side 2004 of the solar cell 2000 to includefront side bus bars 2016, 2018, 2020, 2022, 2024 and on the back side2046 of the solar cell 2000 to include back side bus bars 2048, 2050,2052, 2054, 2056. Front side bus bars 2016, 2024 are formed at locationson the solar cell 2000 similar to those of front side bus bars 1016,1024 of solar cell 1000. The remainder of the front side bus bars 2018,2020, 2022 here are unevenly spaced between the other front side busbars 2016, 2024. In particular, front side bus bar 2018 is formed alongleft edge 2064 of discrete section 2008, front side bus bar 2020 isformed along left edge 2068 of discrete section 2010, and front side busbar 2022 is formed along right edge 2074 of discrete section 2012. Eachfront side bus bar 2016, 2018, 2020, 2022, 2024 has finger linesextending away therefrom. Back side bus bars 2048, 2050, 2052, 2054,2056 are formed at corresponding opposite edge locations on the backside 2046 of the solar cell 2000, as shown in FIG. 21.

In still another exemplary embodiment, as illustrated in FIGS. 22 and23, the solar cell 2200 here has discrete sections 2206, 2208, 2210,2212, 2214 each patterned on the front side 2204 of the solar cell 2200to include front side bus bars 2216, 2218, 2220, 2222, 2224 and on theback side 2246 of the solar cell 2200 to include back side bus bars2248, 2250, 2252, 2254, 2256. Front side bus bars 2216, 2224 are formedat locations on the solar cell 2200 similar to those of front side busbars 1016, 1024 of solar cell 1000. The remainder of the front side busbars 2218, 2220, 2222 are evenly spaced between the other front side busbars 2216, 2024. Front side bus bar 2218 is formed along left edge 2264of discrete section 2208, front side bus bar 2220 is formed along leftedge 2268 of discrete section 2210, and front side bus bar 2222 isformed along left edge 2272 of discrete section 2212. Each front sidebus bar 2216, 2218, 2220, 2222, 2224 has finger lines extending awaytherefrom. Back side bus bars 2248, 2250, 2252, 2254, 2256 are formed atcorresponding opposite edge locations on the back side 2246 of the solarcell 2200, as shown in FIG. 23.

Although the embodiments of the solar cells described above include fivediscrete sections to be cleaved into five strips, other embodimentsinclude solar cells having six discrete sections to be cleaved into sixstrips. Similar to the embodiments above, one or none of the front sidebus bars is formed along an edge of the solar cell.

Turning now to FIGS. 24 and 25, a solar cell 2400 having six discretesections 2406, 2408, 2410, 2412, 2414, 2416 is illustrated. The discretesections 2406, 2408, 2410, 2412, 2414, 2416 are each patterned on thefront side 2402 of the solar cell 2400 to include front side bus bars2418, 2420, 2422, 2424, 2426, 2428, and on the back side 2404 of thesolar cell 2400 to include back side bus bars 2430, 2432, 2434, 2436,2438, 2440. Front side bus bar 2418 is formed at a location on the solarcell 2400 that is away from its left edge 2442, and in particular, alonga right edge 2452 of discrete section 2406. Front side bus bar 2428 isformed along the right edge 2444 of the solar cell 2400, which is alsoalong the right edge 2472 of discrete section 2416. The remainder of thefront side bus bars, 2420, 2422, 2424, 2426 are evenly spaced betweenthe other front side bus bars 2416, 2424. Specifically, front side busbar 2420 is formed along right edge 2456 of discrete section 2408, frontside bus bar 2422 is formed along right edge 2460 of discrete section2410, front side bus bar 2424 is formed along right edge 2464 ofdiscrete section 2412, and front side bus bar 2426 is formed along rightedge 2468 of discrete section 2414. Each front side bus bar 2418, 2420,2422, 2424, 2426, 2428 has finger lines extending away therefrom. Backside bus bars 2430, 2432, 2434, 2436, 2438, 2440 are formed atcorresponding opposite edge locations on the back side 2404 of the solarcell 2400, as shown in FIG. 25.

FIGS. 26 and 27 illustrate another embodiment of, a solar cell 2600having six discrete sections 2606, 2608, 2610, 2612, 2614, 2616. Thediscrete sections 2606, 2608, 2610, 2612, 2614, 2616 are each patternedon the front side 2602 of the solar cell 2600 to include front side busbars 2618, 2620, 2622, 2624, 2626, 2628, and on the back side 2604 ofthe solar cell 2600 to include back side bus bars 2630, 2632, 2634,2636, 2638, 2640. Front side bus bar 2618 is formed at a location on thesolar cell 2600 that is away from its left edge 2642, and in particular,along a right edge 2652 of discrete section 2606. Front side bus bar2628 is formed along the right edge 2644 of the solar cell 2600, whichis also along the right edge 2672 of discrete section 2616. Theremainder of the front side bus bars, 2620, 2622, 2624, 2626 areunevenly spaced between the other front side bus bars 2616.Specifically, front side bus bar 2620 is formed along left edge 2654 ofdiscrete section 2608, front side bus bar 2622 is formed along rightedge 2660 of discrete section 2610, front side bus bar 2626 is formedalong right edge 2664 of discrete section 2612, and front side bus bar2624 is formed along right edge 2668 of discrete section 2614. Eachfront side bus bar 2618, 2620, 2622, 2624, 2626, 2628 has finger linesextending away therefrom. Back side bus bars 2630, 2632, 2634, 2636,2638, 2640 are formed at corresponding opposite edge locations on theback side 2604 of the solar cell 2600, as shown in FIG. 27.

In another embodiment, a solar cell 2800 having six discrete sections2806, 2808, 2810, 2812, 2814, 2816 is illustrated in FIGS. 28 and 29.The discrete sections 2806, 2808, 2810, 2612, 2614, 2616 are eachpatterned on the front side 2802 of the solar cell 2800 to include frontside bus bars 2818, 2820, 2822, 2824, 2826, 2828, and on the back side2804 of the solar cell 2800 to include back side bus bars 2830, 2832,2834, 2836, 2838, 2840. Front side bus bar 2818 is formed away from aleft edge 2842, and in particular, along a right edge 2852 of discretesection 2806. Front side bus bar 2828 is formed along the right edge2844 of the solar cell 2600, which is also along the right edge 2872 ofdiscrete section 2816. The remainder of the front side bus bars 2820,2822, 2824, 2826 are unevenly spaced between the other front side busbars 2818, 2828. Specifically, front side bus bar 2820 is formed alongright edge 2856 of discrete section 2808, front side bus bar 2822 isformed along left edge 2858 of discrete section 2810, front side bus bar2824 is formed along right edge 2864 of discrete section 2812, and frontside bus bar 2826 is formed along right edge 2868 of discrete section2614. Each front side bus bar 2818, 2820, 2822, 2824, 2826, 2828 hasfinger lines extending away therefrom. Back side bus bars 2830, 2832,2834, 2836, 2838, 2840 are formed at corresponding opposite edgelocations on the back side 2804 of the solar cell 2800, as shown in FIG.29.

In still another embodiment, a solar cell 3000 having six discretesections 3006, 3008, 3010, 3012, 3014, 3016 is illustrated in FIGS. 30and 31. The discrete sections 3006, 3008, 3010, 3012, 3014, 3016 areeach patterned on the front side 3002 of the solar cell 3000 to includefront side bus bars 3018, 3020, 3022, 3024, 3026, 3028, and on the backside 3004 of the solar cell 3000 to include back side bus bars 3030,3032, 3034, 3036, 3038, 3040. Front side bus bar 3018 is formed atlocations on the solar cell 3000 that is away from its left edge 3042,and in particular, along a right edge 3052 of discrete section 3006.Front side bus bar 3028 is formed along the right edge 3044 of the solarcell 3000, which is also along the right edge 3072 of discrete section3016. The remainder of the front side bus bars 3020, 3022, 3024, and3026 are unevenly spaced between the other front side bus bars 3018,3028. Specifically, front side bus bar 3020 is formed along right edge3056 of discrete section 3008, front side bus bar 3022 is formed alongright edge 3060 of discrete section 3010, and front side bus bar 3024 isformed along left edge 3066 of discrete section 3014. Each front sidebus bars 3018, 3020, 3022, 3024, 3026, and 3028 has finger linesextending away therefrom. Back side bus bars 3030, 3032, 3034, 3036,3038, and 3040 are formed correspondingly on the back side 3004 of thesolar cell 3000, as shown in FIG. 31.

In still yet another embodiment, a solar cell 3200 having six discretesections 3206, 3208, 3210, 3212, 3214, 3216 is illustrated in FIGS. 32and 33. The discrete sections 3206, 3208, 3210, 3212, 3214, 3216 areeach patterned on the front side 3202 of the solar cell 3200 to includefront side bus bars 3218, 3220, 3222, 3224, 3226, and 3228, and on theback side 3204 of the solar cell 3200 to include back side bus bars3230, 3232, 3234, 3236, 3238, and 3240. Front side bus bar 3218 isformed at locations on the solar cell 3200 that is away from its leftedge 3242, and in particular, along a right edge 3252 of discretesection 3206. Front side bus bar 3228 is formed along the right edge3244 of the solar cell 3200, which is also along the right edge 3272 ofdiscrete section 3216. The remainder of the front side bus bars 3220,3222, 3234, and 3236 are unevenly spaced between the other front sidebus bars 3218, 3228. Specifically, front side bus bar 3220 is formedalong right edge 3256 of discrete section 3208, front side bus bar 3222is formed along left edge 3258 of discrete section 3210, front side busbar 3224 is formed along right edge 3268 of discrete section 3214, andfront side bus bar 3226 is formed along left edge 3266 of discretesection 3214,. Each front side bus bar 3218, 3220, 3222, 3224, 3226, and3228 has finger lines extending away therefrom. Back side bus bars 3230,3232, 3234, 3236, 3238, and 3240 are formed at corresponding oppositeedge locations on the back side 3204 of the solar cell 3200, as shown inFIG. 33.

Even still another embodiment, a solar cell 3400 having six discretesections 3406, 3408, 3410, 3412, 3414, and 3416 is illustrated in FIGS.34 and 35. The discrete sections 3406, 3408, 3410, 3412, 3414, and 3416are each patterned on the front side 3402 of the solar cell 3400 toinclude front side bus bars 3418, 3420, 3422, 3424, 3426, and 3428, andon the back side 3404 of the solar cell 3400 to include back side busbars 3430, 3432, 3434, 3436, 3438, and 3440. Front side bus bar 3418 isformed at locations on the solar cell 3400 that is away from its leftedge 3442, and in particular, along a right edge 3452 of discretesection 3406. Front side bus bar 3428 is formed along the right edge3444 of the solar cell 3400, which is also along the right edge 3472 ofdiscrete section 3416. The remainder of the front side bus bars 3420,3422, and 3426 are unevenly spaced between the other front side bus bars3418, 3428. Specifically, front side bus bar 3420 is formed along leftedge 3454 of discrete section 3408, front side bus bar 3422 is formedalong right edge 3460 of discrete section 3410, front side bus bar 3424is formed along right edge 3464 of discrete section 3412, and front sidebus bar 3426 is formed along left edge 3468 of discrete section 3414.Each front side bus bar 3418, 3420, 3422, 3424, 3426, and 3428 hasfinger lines extending away therefrom. Back side bus bars 3430, 3432,3434, 3436, 3438, and 3440 are formed at corresponding opposite edgelocations on the back side 3404 of the solar cell 3400, as shown in FIG.35.

Another embodiment shown in FIGS. 36 and 37 includes a solar cell 3600having six discrete sections 3606, 3608, 3610, 3612, 3614, and 3616. Thediscrete sections 3606, 3608, 3610, 3612, 3614, and 3616 are eachpatterned on the front side 3602 of the solar cell 3600 to include frontside bus bars 3618, 3620, 3622, 3624, 3626, and 3628, and on the backside 3604 of the solar cell 3600 to include back side bus bars 3630,3632, 3634, 3636, 3638, and 3640. Front side bus bar 3618 is formed atlocations on the solar cell 3600 that is away from its left edge 3642,and in particular, along a right edge 3652 of discrete section 3606.Front side bus bar 3628 is formed along the right edge 3644 of the solarcell 3600, which is also along the right edge 3672 of discrete section3616. The remainder of the front side bus bars 3620, 3622, and 3626 areunevenly spaced between the other front side bus bars 3618, 3628.Specifically, front side bus bar 3620 is formed along right edge 3656 ofdiscrete section 3608, front side bus bar 3622 is formed along left edge3658 of discrete section 3610, front side bus bar 3624 is formed alongleft edge 3662 of discrete section 3612, and front side bus bar 3626 isformed along right edge 3668 of discrete section 3614. Each front sidebus bar 3618, 3620, 3622, 3624, 3626, and 3628 has finger linesextending away therefrom. Back side bus bars 3630, 3632, 3634, 3636,3638, and 3640 are formed at corresponding opposite edge locations onthe back side 3604 of the solar cell 3600, as shown in FIG. 37.

Even still another embodiment, a solar cell 3800 having six discretesections 3806, 3808, 3810, 3812, 3814, and 3816 is illustrated in FIGS.38 and 39. The discrete sections 3806, 3808, 3810, 3812, 3814, and 3816are each patterned on the front side 3802 of the solar cell 3800 toinclude front side bus bars 3818, 3820, 3822, 3824, 3826, and 3828, andon the back side 3804 of the solar cell 3800 to include back side busbars 3830, 3832, 3834, 3836, 3838, and 3840. Front side bus bar 3818 isformed at locations on the solar cell 3800 that is away from its leftedge 3842, and in particular, along a right edge 3852 of discretesection 3806. Front side bus bar 3828 is formed along the right edge3844 of the solar cell 3800, which is also along the right edge 3872 ofdiscrete section 3816. The remainder of the front side bus bars 3820,3822, 3824, and 3826 are unevenly spaced between the other front sidebus bars 3818, 3828. Specifically, front side bus bar 3820 is formedalong left edge 3854 of discrete section 3808, front side bus bar 3822is formed along right edge 3864 of discrete section 3810, front side busbar 3824 is formed along left edge 3866 of discrete section 3812, andfront side bus bar 3826 is formed along right edge 3868 of discretesection 3814. Each front side bus bar 3818, 3820, 3822, 3824, 3826, and3828 has finger lines extending away therefrom. Back side bus bars 3830,3832, 3834, 3836, 3838, and 3840 are formed at corresponding oppositeedge locations on the back side 3804 of the solar cell 3800, as shown inFIG. 39.

In another embodiment, a solar cell 4000 having six discrete sections4006, 4008, 4010, 4012, 4014, 4016 is illustrated in FIGS. 40 and 41.The discrete sections 4006, 4008, 4010, 4012, 4014, 4016 are eachpatterned on the front side 4002 of the solar cell 4000 to include frontside bus bars 4018, 4020, 4022, 4024, 4026, 4028, and on the back side4004 of the solar cell 4000 to include back side bus bars 4030, 4032,4034, 4036, 4038, 4040. Front side bus bar 4018 is formed at locationson the solar cell 4000 that is away from its left edge 4042, and inparticular, along a right edge 4052 of discrete section 4006. Front sidebus bar 4028 is formed along the right edge 4044 of the solar cell 4000,which is also along the right edge 4072 of discrete section 4016. Theremainder of the front side bus bars 4018, 4020, 4022, and 4026 areunevenly spaced between the other front side bus bars 4016, 4028.Specifically, front side bus bar 4020 is formed along left edge 4054 ofdiscrete section 4008, front side bus bar 4022 is formed along left edge4058 of discrete section 4010, front side bus bar 4024 is formed alongright edge 4064 of discrete section 4014, and front side bus bar 4026 isformed along right edge 4068 of discrete section 4014. Each front sidebus bar 4020, 4022, 4024, and 4026 has finger lines extending awaytherefrom. Back side bus bars 4030, 4032, 4034, 4036, 4038, 4040 areformed at corresponding opposite edge locations on the back side 4004 ofthe solar cell 4000, as shown in FIG. 41.

In still another embodiment, a solar cell 4200 having six discretesections 4206, 4208, 4210, 4212, 4214, and 4216 is illustrated in FIGS.42 and 43. The discrete sections 4206, 4208, 4210, 4212, 4214, and 4216are each patterned on the front side 4202 of the solar cell 4200 toinclude front side bus bars 4218, 4220, 4222, 4224, 4226, and 4228, andon the back side 4204 of the solar cell 4200 to include back side busbars 4230, 4232, 4234, 4236, 4238, 4240. Front side bus bar 4218 isformed at locations on the solar cell 4200 that is away from its leftedge 4242, and in particular, along a right edge 4252 of discretesection 4206. Front side bus bar 4228 is formed along the right edge4244 of the solar cell 4200, which is also along the right edge 4272 ofdiscrete section 4216. The remainder of the front side bus bars 4220,4222, 4224, and 4226 are unevenly spaced between the other front sidebus bars 4218, 4228. Specifically, front side bus bar 4220 is formedalong left edge 4254 of discrete section 4208, front side bus bar 4222is formed along right edge 4260 of discrete section 4210, front side busbar 4224 is formed along left edge 4262 of discrete section 4212, andfront side bus bar 4226 is formed along left edge 4266 of discretesection 4214. Each front side bus bar 4218, 4220, 4222, 4224, 4226, and4228 has finger lines extending away therefrom. Back side bus bars 4230,4232, 4234, 4236, 4238, 4240 are formed at corresponding opposite edgelocations on the back side 4204 of the solar cell 4200, as shown in FIG.43.

According to another embodiment, a solar cell 4400 having six discretesections 4406, 4408, 4410, 4412, 4414, and 4416 is illustrated in FIGS.44 and 45. The discrete sections 4406, 4408, 4410, 4412, 4414, and 4416are each patterned on the front side 4402 of the solar cell 4400 toinclude front side bus bars 4418, 4420, 4422, 4424, 4426, and 4428, andon the back side 4404 of the solar cell 4400 to include back side busbars 4430, 4432, 4434, 4436, 4438, and 4440. Front side bus bar 4418 isformed at locations on the solar cell 4400 that is away from its leftedge 4442, and in particular, along a right edge 4452 of discretesection 4406. Front side bus bar 4428 is formed along the right edge4444 of the solar cell 4400, which is also along the right edge 4472 ofdiscrete section 4416. The remainder of the front side bus bars 4420,4422, 4424, and 4426 are unevenly spaced between the other front sidebus bars 4418, 4428. Specifically, front side bus bar 4420 is formedalong left edge 4454 of discrete section 4408, front side bus bar 4422is formed along left edge 4458 of discrete section 4410, front side busbar 4424 is formed along right edge 4464 of discrete section 4412, andfront side bus bar 4426 is formed along left edge 4466 of discretesection 4414. Each front side bus bar 4418, 4420, 4422, 4424, 4426, and4428 has finger lines extending away therefrom. Back side bus bars 4430,4432, 4434, 4436, 4438, 4440 are formed at corresponding opposite edgelocations on the back side 4404 of the solar cell 4400, as shown in FIG.45.

In still another embodiment, a solar cell 4600 having six discretesections 4606, 4608, 4610, 4612, 4614, and 4616 is illustrated in FIGS.46 and 47. The discrete sections 4606, 4608, 4610, 4412, 4414, and 4416are each patterned on the front side 4602 of the solar cell 4600 toinclude front side bus bars 4618, 4620, 4622, 4624, 4626, 4628, and onthe back side 4604 of the solar cell 4600 to include back side bus bars4630, 4632, 4634, 4636, 4638, 4640. Front side bus bar 4618 is formed atlocations on the solar cell 4600 that is away from its left edge 4642,and in particular, along a right edge 4652 of discrete section 4606.Front side bus bar 4628 is formed along the right edge 4644 of the solarcell 4600, which is also along the right edge 4672 of discrete section4616. The remainder of the front side bus bars 4620, 4622, 4624, and4626 are unevenly spaced between the other front side bus bars 4618,4628. Specifically, front side bus bar 4620 is formed along right edge4656 of discrete section 4608, front side bus bar 4622 is formed alongright edge 4660 of discrete section 4610, front side bus bar 4624 isformed along right edge 4664 of discrete section 4612, and front sidebus bar 4626 is formed along left edge 4666 of discrete section 4614.Each front side bus bar 4618, 4620, 4622, 4624, 4626, and 4628 hasfinger lines extending away therefrom. Back side bus bars 4630, 4632,4634, 4636, 4638, and 4640 are formed at corresponding opposite edgelocations on the back side 4604 of the solar cell 4600, as shown in FIG.47.

In still yet another embodiment, a solar cell 4800 having six discretesections 4806, 4808, 4810, 4812, 4814, and 4816 is illustrated in FIGS.48 and 49. The discrete sections 4806, 4808, 4810, 4812, 4814, and 4816are each patterned on the front side 4802 of the solar cell 4800 toinclude front side bus bars 4818, 4820, 4822, 4824, 4826, 4828, and onthe back side 4804 of the solar cell 4800 to include back side bus bars4830, 4832, 4834, 4836, 4838, and 4840. Front side bus bar 4818 isformed at locations on the solar cell 4800 that is away from its leftedge 4842, and in particular, along a right edge 4852 of discretesection 4806. Front side bus bar 4828 is formed along the right edge4844 of the solar cell 4800, which is also along the right edge 4872 ofdiscrete section 4816. The remainder of the front side bus bars 4820,4822, 4824, and 4826 are unevenly spaced between the other front sidebus bars 4818, 4828. Specifically, front side bus bar 4820 is formedalong left edge 4854 of discrete section 4808, front side bus bar 4822is formed along right edge 4860 of discrete section 4810, front side busbar 4824 is formed along left edge 4862 of discrete section 4812, andfront side bus bar 4826 is formed along right edge 4868 of discretesection 4814. Each front side bus bar 4818, 4820, 4822, 4824, 4826, and4828 has finger lines extending away therefrom. Back side bus 4830,4832, 4834, 4836, 4838, and 4840 are formed at corresponding oppositeedge locations on the back side bars 4804 of the solar cell 4800, asshown in FIG. 49.

A solar cell 5000 having six discrete sections 5006, 5008, 5010, 5012,5014, and 5016 is illustrated in FIGS. 50 and 51. The discrete sections5006, 5008, 5010, 5012, 5014, and 5016 are each patterned on the frontside 5002 of the solar cell 5000 to include front side bus bars 5018,5020, 5022, 5024, 5026, and 5028, and on the back side 5004 of the solarcell 5000 to include back side bus bars 5030, 5032, 5034, 5036, 5038,and 5040. Front side bus bar 5018 is formed at locations on the solarcell 5000 that is away from its left edge 5042, and in particular, alonga left edge 5042 of discrete section 5006. Front side bus bar 5028 isformed along the left edge 5044 of the solar cell 5000, which is alsoalong the left edge 5070 of discrete section 5016. The remainder of thefront side bus bars 5020, 5022, 5024 and 5026 are unevenly spacedbetween the other front side bus bars 5018, 5028. Specifically, frontside bus bar 5020 is formed along right edge 5056 of discrete section5008, front side bus bar 5022 is formed along right edge 5060 ofdiscrete section 5010, front side bus bar 5024 is formed along rightedge 5064 of discrete section 5012, and front side bus bar 5026 isformed along right edge 5068 of discrete section 5014. Each front sidebus bar 5018, 5020, 5022, 5024, 5050, and 5028 has finger linesextending away therefrom. Back side bus bars 5030, 5032, 5034, 5036,5038, and 5040 are formed at corresponding opposite edge locations onthe back side 5004 of the solar cell 5000, as shown in FIG. 51.

In another embodiment, a solar cell 5200 having six discrete sections5206, 5208, 5210, 5212, 5214, 5216 is illustrated. Generally in thesesolar cells 5200 having six discrete sections, the front side bus barsare not both formed along an edge so as to avoid edge leakage andimprove the shunt resistance, resulting in higher yield and better lowirradiation performance (for example, in cells having a p-n junctionthickness of about 0.4um, and a base thickness of about 190 um).Further, in some embodiments of the solar cell in which a symmetricalpattern design is included on both the front and back sides of the solarcell, such a pattern may provide a consistent conductive distancebetween a front side pole and back side pole. In particular, thesymmetrical pattern has been found to improve the consistency andaccuracy in cell efficiency testing due to the uniform resistance lossbetween strips. Further, for those solar cells having symmetricalpattern designs, better finger and bus-bar resolution result, whichallows the screen print to last longer due to the uniform mechanicalpressure used in their formation.

Returning to FIG. 52, the discrete sections 5206, 5208, 5210, 5212,5214, and 5216 are each patterned on the front side 5202 of the solarcell 5200 to include front side bus bars 5218, 5220, 5222, 5224, 5226,and 5228, and on the back side 5204 of the solar cell 5200 to includeback side bus bars 5230, 5232, 5234, 5236, 5238, 5240. Front side busbar 5218 is formed at locations on the solar cell 5200 that is along itsleft edge 5242, and in particular, along a left edge 5050 of discretesection 5206. Front side bus bar 5228 is formed away the left edge 5244of the solar cell 5200, which is also along the left edge 5270 ofdiscrete section 5216. The remainder of the front side bus bars 5220,5222, 5224, and 5226 are evenly spaced between the other front side busbars 5218, 5228. Specifically, front side bus bar 5220 is formed alongright edge 5256 of discrete section 5208, front side bus bar 5222 isformed along right edge 5260 of discrete section 5210, front side busbar 5224 is formed along right edge 5264 of discrete section 5212, andfront side bus bar 5226 is formed along left edge 5266 of discretesection 5214. Each front side bus bar 5218, 5220, 5222, 5224, 5226, and5228 has finger lines extending away therefrom. Back side bus bars 5230,5232, 5234, 5236, 5238, and 5240 are formed at corresponding oppositeedge locations on the back side 5204 of the solar cell 5200, as shown inFIG. 53.

In another embodiment, a solar cell 5400 having six discrete sections5406, 5408, 5410, 5412, 5414, and 5416 is illustrated in FIGS. 54 and55. The discrete sections 5406, 5408, 5410, 5412, 5414, and 5416 areeach patterned on the front side 5402 of the solar cell 5400 to includefront side bus bars 5418, 5420, 5422, 5424, 5426, and 5428, and on theback side 5404 of the solar cell 5400 to include back side bus bars5430, 5432, 5434, 5436, 5438, and 5440. Front side bus bar 5418 isformed at locations on the solar cell 5400 that is along its left edge5442, and in particular, along a left edge 5450 of discrete section5406. Front side bus bar 5428 is formed away from the edge 5472 of thesolar cell 5400, which is also along the left edge 5470 of discretesection 5416. The remainder of the front side bus bars 5420, 5422, 5424,and 5426 are unevenly spaced between the other front side bus bars 5418,5428. Specifically, front side bus bar 5420 is formed along right edge5456 of discrete section 5408, front side bus bar 5422 is formed alongleft edge 5458 of discrete section 5410, front side bus bar 5424 isformed along right edge 5464 of discrete section 5412, and front sidebus bar 5426 is formed along right edge 5468 of discrete section 5414.Each front side bus bar 5418, 5420, 5422, 5424, 5426, and 5428 hasfinger lines extending away therefrom. Back side bus bars 5430, 5432,5434, 5436, 5438, and 5440 are formed at corresponding opposite edgelocations on the back side 5404 of the solar cell 5400, as shown in FIG.55.

In still another embodiment, a solar cell 5600 having six discretesections 5606, 5608, 5610, 5612, 5614, and 5616 is illustrated in FIGS.56 and 57. The discrete sections 5606, 5608, 5610, 5612, 5614, and 5616are each patterned on the front side 5602 of the solar cell 5600 toinclude front side bus bars 5618, 5620, 5622, 5624, 5626, and 5628, andon the back side 5604 of the solar cell 5600 to include back side busbars 5630, 5632, 5634, 5636, 5638, and 5640. Front side bus bar 5618 isformed at locations on the solar cell 5600 that is along its left edge5642, and in particular, along a left edge 5650 of discrete section5606. Front side bus bar 5628 is formed along the away from edge 5644 ofthe solar cell 5600, which is also along the left edge 5670 of discretesection 5616. The remainder of the front side bus bars 5620, 5622, 5624,and 5626 are unevenly spaced between the other front side bus bars 5618,5628. Specifically, front side bus bar 5620 is formed along left edge5654 of discrete section 5608, front side bus bar 5622 is formed alongright edge 5660 of discrete section 5610, front side bus bar 5624 isformed along right edge 5664 of discrete section 5612, and front sidebus bar 5626 is formed along right edge 5668 of discrete section 5614.Each front side bus bar 5618, 5620, 5622, 5624, 5626, and 5628 hasfinger lines extending away therefrom. Back side bus bars 5630, 5632,5634, 5636, 5638, and 5640 are formed at corresponding opposite edgelocations on the back side 5604 of the solar cell 5600, as shown in FIG.57.

In yet another embodiment, a solar cell 5800 having six discretesections 5806, 5808, 5810, 5812, 5814, and 5816 is illustrated in FIGS.58 and 59. The discrete sections 5806, 5808, 5810, 5812, 5814, and 5816are each patterned on the front side 5802 of the solar cell 5800 toinclude front side bus bars 5818, 5820, 5822, 5824, 5826, and 5858, andon the back side 5804 of the solar cell 5800 to include back side busbars 5830, 5832, 5834, 5836, 5838, and 5840. Front side bus bar 5818 isformed at locations on the solar cell 5800 that are away from its leftedge 5842, and in particular, along a right edge 5852 of discretesection 5806. Front side bus bar 5828 is formed away from the right edge5844 of the solar cell 5800, which is also along the left edge 5870 ofdiscrete section 5816. The remainder of the front side bus bars 5820,5822, 5824, and 5826 are unevenly spaced between the other front sidebus bars 5818, 5828. Specifically, front side bus bar 5820 is formedalong right edge 5856 of discrete section 5808, front side bus bar 5822is formed along right edge 5860 of discrete section 5810, front side busbar 5824 is formed along right edge 5864 of discrete section 5812, andfront side bus bar 5826 is formed along right edge 5868 of discretesection 5814. Each front side bus bar 5818, 5820, 5822, 5824, 5826, and5828 has finger lines extending away therefrom. Back side bus bars 5830,5832, 5834, 5836, 5838, and 5840 are formed at corresponding oppositeedge locations on the back side 5804 of the solar cell 5800, as shown inFIG. 59.

In another embodiment, a solar cell 6000 having six discrete sections6006, 6008, 6010, 6012, 6014, and 6016 is illustrated in FIGS. 60 and61. The discrete sections 6006, 6008, 6010, 6012, 6014, and 6016 areeach patterned on the front side 6002 of the solar cell 6000 to includefront side bus bars 6018, 6020, 6022, 6024, 6026, 6028, and on the backside 6004 of the solar cell 6000 to include back side bus bars 6030,6032, 6034, 6036, 6038, 6040. Front side bus bar 6018 is formed atlocations on the solar cell 6000 that is away from its left edge 6042,and in particular, along a right edge 6052 of discrete section 6006.Front side bus bar 6028 is formed away from the right edge 6044 of thesolar cell 6000, which is also along the left edge 6070 of discretesection 6016. The remainder of the front side bus bars 6020, 6022, 6024,and 6026 are unevenly spaced between the other front side bus bars 6018,6028. Specifically, front side bus bar 6020 is formed along right edge6056 of discrete section 6008, front side bus bar 6022 is formed alongright edge 6060 of discrete section 6010, front side bus bar 6024 isformed along right edge 6064 of discrete section 6012, and front sidebus bar 6026 is formed along left edge 6066 of discrete section 6014.Each front side bus bar 6018, 6020, 6022, 6024, 6026, and 6028 hasfinger lines extending away therefrom. Back side bus bars 6030, 6032,6034, 6036, 6038, and 6040 are formed at corresponding opposite edgelocations on the back side 6004 of the solar cell 6000, as shown in FIG.61.

In yet another embodiment, a solar cell 6200 having six discretesections 6206, 6208, 6210, 6212, 6214, and 6216 is illustrated in FIGS.62 and 63. The discrete sections 6206, 6208, 6210, 6212, 6214, and 6216are each patterned on the front side 6202 of the solar cell 6200 toinclude front side bus bars 6218, 6220, 6222, 6224, 6226, and 6228, andon the back side 6204 of the solar cell 6200 to include back side busbars 6230, 6232, 6234, 6236, 6238, and 6240. Front side bus bar 6220 isformed at locations on the solar cell 6200 that is away from its leftedge 6242, and in particular, along a right edge 6252 of discretesection 6206. Front side bus bar 6228 is formed away from the right edge6244 of the solar cell 6200, which is also along the left edge 6270 ofdiscrete section 6216. The remainder of the front side bus bars 6220,6222, 6224, and 6226 are unevenly spaced between the other front sidebus bars 6218, 6228. Specifically, front side bus bar 6220 is formedalong right edge 6256 of discrete section 6208, front side bus bar 6222is formed along right edge 6260 of discrete section 6210, front side busbar 6224 is formed along left edge 6262 of discrete section 6212, andfront side bus bar 6226 is formed along right edge 6268 of discretesection 6214. Each front side bus bar 6218, 6220, 6222, 6224, 6226, and6228 has finger lines extending away therefrom. Back side bus bars 6230,6232, 6234, 6236, 6238, and 6240 are formed at corresponding oppositeedge locations on the back side 6204 of the solar cell 6200, as shown inFIG. 63.

In yet another embodiment, a solar cell 6400 having six discretesections 6406, 6408, 6410, 6412, 6414, and 6416 is illustrated in FIGS.64 and 65. The discrete sections 6406, 6408, 6410, 6412, 6414, and 6416are each patterned on the front side 6402 of the solar cell 6400 toinclude front side bus bars 6418, 6420, 6422, 6424, 6426, and 6428, andon the back side 6404 of the solar cell 6400 to include back side busbars 6430, 6432, 6434, 6436, 6438, and 6440. Front side bus bar 6418 isformed at locations on the solar cell 6400 that is away from its leftedge 6442, and in particular, along a right edge 6452 of discretesection 6406. Front side bus bar 6428 is formed away from the right edge6444 of the solar cell 6400, which is also along the left edge 6470 ofdiscrete section 6416. The remainder of the front side bus bars 6420,6422, 6424, and 6426 are unevenly spaced between the other front sidebus bars 6418, 6426. Specifically, front side bus bar 6420 is formedalong right edge 6456 of discrete section 6408, front side bus bar 6422is formed along left edge 6458 of discrete section 6410, front side busbar 6424 is formed along right edge 6464 of discrete section 6412, andfront side bus bar 6426 is formed along right edge 6468 of discretesection 6414. Each front side bus bar 6418, 6420, 6422, 6424, 6426, and6428 has finger lines extending away therefrom. Back side bus bars 6430,6432, 6434, 6436, 6438, and 6440 are formed at corresponding oppositeedge locations on the back side 6404 of the solar cell 6400, as shown inFIG. 65.

In still another embodiment, a solar cell 6600 having six discretesections 6606, 6608, 6610, 6612, 6614, and 6616 is illustrated in FIGS.66 and 67. The discrete sections 6606, 6608, 6610, 6612, 6614, and 6616are each patterned on the front side 6602 of the solar cell 6600 toinclude front side bus bars 6618, 6620, 6622, 6624, 6626, and 6628, andon the back side 6604 of the solar cell 6600 to include back side busbars 6630, 6632, 6634, 6636, and 6638, and 6640. Front side bus bar 6618is formed at locations on the solar cell 6600 that is away from its leftedge 6642, and in particular, along a right edge 6652 of discretesection 6606. Front side bus bar 6628 is formed away from the right edge6644 of the solar cell 6600, which is also along the left edge 6670 ofdiscrete section 6616. The remainder of the front side bus bars 6620,6622, 6624, and 6628 are unevenly spaced between the other front sidebus bars 6618, 6628. Specifically, front side bus bar 6620 is formedalong left edge 6654 of discrete section 6608, front side bus bar 6622is formed along right edge 6660 of discrete section 6610, front side busbar 6624 is formed along right edge 6664 of discrete section 6612, andfront side bus bar 6626 is formed along right edge 6668 of discretesection 6614. Each front side bus bar 6618, 6620, 6622, 6624, 6626, and6628 has finger lines extending away therefrom. Back side bus bars 6630,6632, 6634, 6636, 6638, and 6640 are formed at corresponding oppositeedge locations on the back side 6604 of the solar cell 6600, as shown inFIG. 67.

In yet another embodiment, a solar cell 6800 having six discretesections 6806, 6808, 6810, 6812, 6814, and 6816 is illustrated in FIGS.68 and 69. The discrete sections 6806, 6808, 6810, 6812, 6814, and 6816are each patterned on the front side 6802 of the solar cell 6800 toinclude front side bus bars 6818, 6820, 6822, 6824, 6826, and 6828, andon the back side 6804 of the solar cell 6800 to include back side busbars 6830, 6832, 6834, 6836, 6838, and 6840. Front side bus bar 6818 isformed at locations on the solar cell 6800 that is away from its leftedge 6842, and in particular, along a right edge 6852 of discretesection 6806. Front side bus bar 6828 is formed away from right edge6844 of the solar cell 6800, which is also along the left edge 6870 ofdiscrete section 6816. The remainder of the front side bus bars 6820,6822, 6824, and 6826 are unevenly spaced between the other front sidebus bars 6818, 6828. Specifically, front side bus bar 6820 is formedalong right edge 6856 of discrete section 6808, front side bus bar 6822is formed along right edge 6860 of discrete section 6810, front side busbar 6824 is formed along left edge 6862 of discrete section 6812, andfront side bus bar 6826 is formed along right edge 6866 of discretesection 6814. Each front side bus bar 6818, 6820, 6822, 6824, 6826, and6828 has finger lines extending away therefrom. Back side bus bars 6830,6832, 6834, 6836, 6838, and 6840 are formed at corresponding oppositeedge locations on the back side 6804 of the solar cell 6800, as shown inFIG. 69.

FIGS. 70 and 71 illustrate a solar cell 7000 having six discretesections 7006, 7008, 7010, 7012, 7014, and 7016 in accordance with anembodiment. The discrete sections 7006, 7008, 7010, 7012, 7014, and 7016are each patterned on the front side 7002 of the solar cell 7000 toinclude front side bus bars 7018, 7020, 7022, 7024, 7026, and 7028, andon the back side 7004 of the solar cell 7000 to include back side busbars 7030, 7032, 7034, 7036, 7038, and 7040. Front side bus bar 7018 isformed at locations on the solar cell 7000 that is away from its leftedge 7042, and in particular, along a right edge 7052 of discretesection 7006. Front side bus bar 7028 is formed away from right edge7044 of the solar cell 7000, which is also along the left edge 7070 ofdiscrete section 7016. The remainder of the front side bus bars 7020,7022, 7024, and 7026 are unevenly spaced between the other front sidebus bars 7018, 7028. Specifically, front side bus bar 7020 is formedalong right edge 7056 of discrete section 7008, front side bus bar 7022is formed along left edge 7058 of discrete section 7010, front side busbar 7024 is formed along right edge 7060 of discrete section 7012, andfront side bus bar 7024 is formed along left edge 7062 of discretesection 7014. Each front side bus bar 7018, 7020, 7022, 7024, 7026, and7028 has finger lines extending away therefrom. Back side bus bars 7030,7032, 7034, 7036, 7038, and 7040 are formed at corresponding oppositeedge locations on the back side 7004 of the solar cell 7000, as shown inFIG. 71.

In another embodiment, FIGS. 72 and 73 illustrate a solar cell 7200having six discrete sections 7206, 7208, 7210, 7212, 7214, and 7216. Thediscrete sections 7206, 7208, 7210, 7212, 7214, and 7216 are eachpatterned on the front side 7202 of the solar cell 7200 to include frontside bus bars 7218, 7220, 7222, 7224, 7226, and 7228, and on the backside 7204 of the solar cell 7200 to include back side bus bars 7230,7232, 7234, 7236, 7238, and 7240. Front side bus bar 7218 is formed atlocations on the solar cell 7200 that is away from its left edge 7242,and in particular, along a right edge 7252 of discrete section 7206.Front side bus bar 7228 is formed away from the right edge 7244 of thesolar cell 7200, which is also along the left edge 7270 of discretesection 7216. The remainder of the front side bus bars 7220, 7222, 7224,and 7226 are unevenly spaced between the other front side bus bars 7218,7228. Specifically, front side bus bar 7220 is formed along left edge7254 of discrete section 7208, front side bus bar 7222 is formed alongright edge 7260 of discrete section 7210, front side bus bar 7224 isformed along right edge 7264 of discrete section 7212, and front sidebus bar 7226 is formed along left edge 7266 of discrete section 7214.Each front side bus bar 7218, 7220, 7222, 7224, 7226, and 7228 hasfinger lines extending away therefrom. Back side bus bars 7230, 7232,7234, 7236, 7238, and 7240 are formed at corresponding opposite edgelocations on the back side 7204 of the solar cell 7200, as shown in FIG.73.

In accordance with another embodiment, FIGS. 74 and 75 illustrate asolar cell 7400 having six discrete sections 7406, 7408, 7410, 7412,7414, 7416. The discrete sections 7406, 7408, 7410, 7412, 7414, and 7416are each patterned on the front side 7402 of the solar cell 7400 toinclude front side bus bars 7418, 7420, 7422, 7424, 7426, and 7428, andon the back side 7404 of the solar cell 7400 to include back side busbars 7430, 7432, 7434, 7436, 7438, and 7440. Front side bus bar 7418 isformed at locations on the solar cell 7400 that is away from its leftedge 7442, and in particular, along a right edge 7452 of discretesection 7406. Front side bus bar 7428 is formed away from the right edge7444 of the solar cell 7400, which is also along the left edge 7470 ofdiscrete section 7416. The remainder of the front side bus bars 7420,7422, 7424, and 7426 are unevenly spaced between the other front sidebus bars 7418, 7428. Specifically, front side bus bar 7420 is formedalong right edge 7454 of discrete section 7408, front side bus bar 7422is formed along right edge 7460 of discrete section 7410, front side busbar 7424 is formed along left edge 7462 of discrete section 7412, andfront side bus bar 7426 is formed along right edge 7468 of discretesection 7414. Each front side bus bar 7418, 7420, 7422, 7424, 7426, 7428and has finger lines extending away therefrom. Back side bus bars 7430,7432, 7434, 7436, 7438, and 7440 are formed at corresponding oppositeedge locations on the back side 7404 of the solar cell 7400, as shown inFIG. 75.

According to another embodiment, FIGS. 76 and 77 illustrate a solar cell7000 having six discrete sections 7606, 7608, 7610, 7612, 7614, and7616. The discrete sections 7606, 7608, 7610, 7612, 7614, and 7616 areeach patterned on the front side 7602 of the solar cell 7600 to includefront side bus bars 7618, 7620, 7622, 7624, 7626, and 7628, and on theback side 7604 of the solar cell 7600 to include back side bus bars7630, 7632, 7634, 7636, 7638, and 7640. Front side bus bar 7618 isformed at locations on the solar cell 7600 that is away from its leftedge 7642, and in particular, along a right edge 7652 of discretesection 7606. Front side bus bar 7628 is formed away from the right edge7644 of the solar cell 7600, which is also along theleft edge 7670 ofdiscrete section 7616. The remainder of the front side bus bars 7620,7622, 7624, and 7626 are unevenly spaced between the other front sidebus bars 7618, 7628. Specifically, front side bus bar 7618 is formedalong left edge 7654 of discrete section 7608, front side bus bar 7622is formed along left edge 7658 of discrete section 7610, front side busbar 7624 is formed along right edge 7664 of discrete section 7612, andfront side bus bar 7626 is formed along right edge 7668 of discretesection 7614. Each front side bus bar 7618, 7620, 7622, 7624, 7626, and7628 has finger lines extending away therefrom. Back side bus bars 7630,7632, 7634, 7636, 7638, and 7640 are formed at corresponding oppositeedge locations on the back side 7604 of the solar cell 7600, as shown inFIG. 77.

No matter the particular configuration, the solar cell is ultimatelyused to form a solar module. In this regard, with reference to FIG. 78,a solar cell is obtained at step 7802 of method 7800. In an embodiment,the solar cell is tested, for example, using flash testing. Inembodiments of solar cells including 5 strips, by grouping two bus-barsadjacent each other on the front side of the solar cell, three sets ofprobes can be used to contact bus-bars in flash testing, which mayreduce the impact of shadow produced by the probes when a light isshined on the solar cell. Similarly, in embodiments in which 6 stripsare included, by grouping two bus-bars adjacent each other, only fivesets of probes may be used in flash testing instead of six probes;alternatively, by grouping two sets of bus-bars adjacent each other,only four sets of probes (rather than six probes) may be used in flashtesting.

The solar cell is cut at step 7804. Specifically, scribe lines areformed into the back surface of the solar cell so that when the solarcell is broken, the split occurs in the gap on the front surface of thesolar cell between the discrete cells. Each scribe line has a depth ofbetween about 10% and about 90% of wafer thickness. In an embodiment,the scribe lines extend across the solar cell from edge to edge. Inanother embodiment, one or both of the scribe lines extends from oneedge to just short of an opposite edge of the solar cell. An exemplaryembodiment of a scribed solar cell 7900 is illustrated in FIG. 79. Asshown, the scribed solar cell 7900 has a back side 7902 having fivediscrete sections 7904, 7906, 7908, 7910, 7912, with back side bus bars7914, 7916, 7918, 7920, 7922, 7924. Scribe lines 7926, 7928, 7930, 7932are formed between corresponding discrete sections 7904, 7906, 7908,7910, 7912. Although five discrete sections are included, more or fewerare included in other embodiments of the solar cell. The scribe linesmay be formed using a laser, a dicing saw and the like. In anembodiment, as illustrated in FIG. 80, a solar cell 8000 is placed on aplatform 8002 back side 8004 facing up so that scribe lines 8006, 8008,8010 of the solar cell 8000 may be formed. One or more lasers 8012,8014, 8016 are aligned at locations on the solar sell to form the scribelines 8006, 8008, 8010 to thereby allow the solar cell 8000 to besingulated into strips. A front side view of the solar cell 8000singulated into strips 8018, 8020, 8022, 8024, 8026 is illustrated inFIG. 81.

Next, the cut solar cell is split at step 7806. In an embodiment inwhich the solar cell may be singulated, the solar cell is placed on avacuum chuck including a plurality of fixtures which are alignedadjacent each other to form a base. The vacuum chuck is selected so thatthe number of fixtures matches the number of discrete sections of thesolar cell to be singulated into strips. Each fixture has apertures orslits, which provide openings communicating with a vacuum. The vacuum,when desired, may be applied to provide suction for mechanicallytemporarily coupling the solar cell to the top of the base. To singulatethe solar cell, the solar cell is placed on the base such that the eachdiscrete section is positioned on top of a corresponding one of thefixtures. The vacuum is powered on and suction is provided to maintainthe solar cell in position on the base. Next, all of the fixtures moverelative to each other. In an embodiment, multiple ones of the fixturesmove a certain distance away from neighboring fixtures thereby causingthe discrete sections of the solar cell to likewise move from each otherand form resulting strips. In another embodiment, multiple ones of thefixtures are rotated or twisted relative to their longitudinal axesthereby causing the discrete sections of the solar cell to likewise moveand form resulting strips. The rotation or twisting of the fixtures maybe effected in a predetermined sequence, in an embodiment, so that nostrip is twisted in two directions at once. In still another embodiment,mechanical pressure is applied to the back surface of the solar cell tosubstantially simultaneously break the solar cell into the strips. Itwill be appreciated that in other embodiments, other processes by whichthe solar cell is singulated alternatively may be implemented.

After the solar cell is singulated, the strips are sorted in step 7808.In particular, as shown in FIG. 81, the left-most and right-most strips8018, 8026 have chamfered corners and, as a result, have dimensions thatare different from strips 8020, 8022, 8024, which have non-chamferedcorners and substantially identical dimensions. In an embodiment,sorting strips is achieved using an auto-optical sorting process. Inanother embodiment, the strips are sorted according to their positionrelative to the full solar cell. After sorting, strips 8018, 8026 havingchamfered corners are segregated from those strips 8020, 8022, 8024having non-chamfered corners. During sorting, strips can be arranged toalign the bus bars into desired postions.

With continued reference to FIG. 78, similarly dimensioned strips arethen overlapped to form a string in step 7810. In an embodiment, anelectrically-conductive adhesive 8202 is applied to a front surface ofthe strip 8204 along an edge of that is opposite the edge along whichits back side bus bar is formed, as depicted in FIG. 82. In anotherembodiment, the electrically-conductive adhesive is applied to a backsurface of the strip on the back side bus bar. The adhesive may beapplied as a single continuous line, as a plurality of dots, dash lines,for example, by using a deposition-type machine configured to dispenseadhesive material to a bus bar surface. In an embodiment, the adhesiveis deposited such that it is shorter than the length of a correspondingbus bar and has a width and thickness to render sufficient adhesion andconductivity. After the adhesive is deposited onto the strip 8204, thestrip 8204 and a second, similarly dimensioned strip 8206 are alignedsuch that the back side bus bar of one strip 8206 overlaps with thefront side bus bar of the other strip 8204, or alternatively, the frontside bus bar of one strip overlaps with the back side bus bar ofanother. The steps of applying adhesive and aligning and overlapping thestrips are repeated until a desired number of strips are adhered to formthe string. In an embodiment, the string includes 15 to 100 strips.Although step 7810 is described as being performed on two strips, one orboth of the strips may be pre-adhered to one or more other strips.

FIG. 83 illustrates a string 8300 of chamfered corner strips 8302, 8304,8306 where the back side bus bar of each strip 8302, 8304, 8306 overlapsand is disposed over the front side bus bar of an adjacent strip. Here,15 to 100 strips make up the string 8300. An end of the string 8300includes a metal foil soldered or electrically connected to the bus barof each end strip which will be further connected to a moduleinterconnect bus bar so that two or more strings together form thecircuit of a solar module, as will be discussed in detail in subsequentparagraphs below. In another embodiment, the module interconnect busbarcan be directly soldered or electrically connected to the bus bar of theend strip to form the circuit. In another embodiment as illustrated inFIG. 84, non-chamfered strips 8402, 8404, 8406 are adhered to each otherto form a string 8400. Similar to the string 8300 shown in FIG. 83, thestring 8400 in FIG. 84 includes 15 to 100 strips and each strip isoverlapped such that the back side bus bar of each strip overlaps and isdisposed over the front side bus bar of an adjacent strip. The string8400 of FIG. 84 also includes electrical connections for coupling toanother similarly configured string. No matter the particularconfiguration, the strings 400, 8300, 8400 may include more or fewerstrips.

FIGS. 85A and 86A are front and back views, respectively, of a solarmodule 8500A in accordance with an embodiment. As noted briefly above,the solar module 8500A includes a back sheet 8502A and a frame 8503Asurrounding all four edges of the back sheet 8502A. The back sheet 8502Ais formed from polymer material, and the frame 8503A is formed fromanodized aluminum or another lightweight rigid material.

Strings 8504A, 8506A, 8508A, 8510A, 8512A, 8514A, 8516A, 8518A, 8520A,8522A of strips, ten of which are shown here, are disposed over the backsheet 8502A. Although not specifically depicted, it will be appreciatedthat a glass layer is disposed over the strips and electricalconnections associated therewith for protective purposes. Here, thestrips are non-chamfered and have squared-off corners. The strings8504A, 8506A, 8508A, 8510A, 8512A, 8514A, 8516A, 8518A, 8520A, 8522A aredisposed side-by-side lengthwise, and as a result, each strip in eachstring extends along the back sheet 8502A lengthwise so that the stripsextend end-to-end.

In an embodiment, the edges of two adjacent strings 8504A, 8506A, 8508A,8510A, 8512A, 8514A, 8516A, 8518A, 8520A, 8522A may be spaced apartproviding a gap therebetween. As illustrated in FIG. 87, which is aclose up view of a portion of the solar module 8500A encircled by “A”, agap 8702A has a uniform width between the two adjacent strings 8504A,8506A in a range of between about 1 mm and about 5 mm. In anotherembodiment, the edges of two or more of the strings 8504A, 8506A, 8508A,8510A, 8512A, 8514A, 8516A, 8518A, 8520A, 8522A are immediately adjacenteach other.

The strings 8504A, 8506A, 8508A, 8510A, 8512A, 8514A, 8516A, 8518A,8520A, 8522A are electrically coupled to the top bus bar 8524A and thebottom bus bars 8528A, 8530A each extending a length of the back sheet8502A on opposite edges. In an embodiment, a first string set 8525A offive strings 8504A, 8506A, 8508A, 8510A, 8512A is connected via the topbus bar 8524A and bottom bus bar 8528A, while a second string set 8527Amaking up the other five strings 8514A, 8516A, 8518A, 8520A, 8522A isconnected via top bus bar and bottom bus bar 8530A. Each connectionincludes a conductive ribbon material adhered at one end to acorresponding strip and at another end to a corresponding bus bar. Inthis way, the strings 8504A, 8506A, 8508A, 8510A, 8512A of the firststring set 8525A are connected in parallel, the strings 8514A, 8516A,8518A, 8520A, 8522A of the second string set 8527A are connected inparallel, while the string sets 8525A, 8527A themselves are connected inseries. An isolation strip 8532A (shown in FIG. 88) is disposed betweenthe two string sets 8525A, 8527A to provide support between the stringsets 8525A, 8527A. The isolation strip 8532A is greater in length thanthe strings and is sufficiently wide to permit the adjacent strings8512A, 8514A of the two string sets 8525A, 8527A, respectively, tooverlap a portion of the isolation strip 8532A. As detailed in FIG. 88,in an embodiment, the isolation strip 8532A has a squared off end 8534Aand a tabbed end 8536A being wider than the squared off end 8534A. Thesquared off end extends past the strings 8512A, 8514A, in an embodiment,and a portion of the top bus bar 8524A is disposed across its width. Anelectrically conductive ribbon 8538A extends substantiallyperpendicularly from the top bus bar 8524A along almost an entire lengthof the isolation strip down a middle of the tabbed end 8536A terminatingjust beyond where the tabbed end 8536A begins. Two additionalelectrically conductive ribbons 8540A, 8542A are disposed over thetabbed end 8536A on either side of the electrically conductive ribbon8538A. The additional electrically conductive ribbons 8540A, 8542A serveas hidden interconnects to connect the strings 8525A, 8527A to ajunction box 8550. Fix tape 8544A is used to maintain the isolationstrip 8532A and the conductive ribbons 8538A, 8540A, 8542A in positionrelative to the strings 8512A, 8514A. In accordance with one embodiment,the series connection of the first string set 8525A to the second stringset 8527A can be made by attaching the negative side of the first stringset 8525A and the positive side of the second string set 8527A to acommon bus bar. Alternatively, positive sides of both the first andsecond string sets 8525A and 8527A may be placed on the same side of thesolar module and a cable, wire, or other connector may be used toelectrically connect the negative side of the first string set 8525A tothe positive side of the second string set 8527A. This secondconfiguration promotes efficiency in manufacturing by allowing allstring sets to be placed in the solar module without reorientation ofone of them, and reduces the size of the bus bars, as well as making allbus bars of similar length rather than having one side be long and theother side formed of two short bus bars, thus reducing the number ofcomponents of the entire module.

As shown in FIG. 86A, a back side 8546A of the solar module 8500Aincludes the back sheet 8502A to which a junction box 8550A is attached.In an embodiment, the junction box 8550A does not include a bypassdiode. In another embodiment, the junction box 8550A includes one ormore bypass diodes disposed therein.

FIGS. 85B and 86B are front and back views, respectively, of a solarmodule 8500B in accordance with another embodiment. Here, the solarmodule 8500B includes a back sheet 8502B and a frame 8503B surroundingall four edges of the back sheet 8502B. The back sheet 8502B is formedfrom polymer material, and the frame 8503B is formed from anodizedaluminum.

Strings 8504B, 8506B, 8508B, 8510B, 8512B, 8514B, 8516B, 8518B, 8520B,8522B of strips, ten of which are shown here, are disposed over the backsheet 8502B, and configured in a manner similar to those of solar module8500A. The strips are rectangular in shape and are typically covered bya glass layer 8505B and an adhesive layer 8507B (both shown in FIGS. 95and 96).

The strings 8504B, 8506B, 8508B, 8510B, 8512B, 8514B, 8516B, 8518B,8520B, 8522B are electrically coupled to top bus bars 8523B, 8524B (FIG.95) along one edge and bottom bus bars 8528B, 8530B along an oppositeedge. Specifically, strings 8504B, 8506B, 8508B, 8510B, 8512B arecoupled to one top bus bar 8523B along one edge, and bus bar 8528B alongan opposite edge to form a first string set 8525B, and strings 8514B,8516B, 8518B, 8520B, 8522B are coupled to a separate bus bar 8524B alongone edge, and bus bar 8530B along an opposite edge to form a secondstring set 8527B. The bus bars 8523B, 8524B, 8528B, 8530B are each inthe form of a ribbon, in an embodiment. In another embodiment, eachconnection includes a conductive ribbon material adhered at one end to acorresponding strip and at another end to a corresponding bus bar. FIG.94 is a top view of a ribbon configuration of a bus bar 9400, inaccordance with an embodiment. The ribbon bus bar 9400 is in the form ofa thin metallized tape having a solid edge 9402 disposed substantiallyparallel with a long edge of the module 8500B and a notched edge 9404that is disposed closest to the strings (for example, strings 8504B,8506B, 8508B, 8510B, 8512B or strings 8514B, 8516B, 8518B, 8520B,8522B). Notches 9406 formed along the notched edge 9404 aresubstantially equally spaced along the length of the ribbon bus bar9400, in an embodiment so that when the corresponding strips of thestrings are soldered to the ribbon bus bar 9400, soldering stresses arereduced. Otherwise, high soldering stresses could cause unwantedmicrocracks in one or more of the strips, which could affect productyield and reliability. In another embodiment, the notches 9406 areunequally spaced. Openings formed in two substantially parallel rows9408, 9410 are included in the ribbon bus bar 9400, where the openingsof one row 9408 are located between adjacent notches 9406, and eachopening of the other row 9410 is located over a corresponding notch9406.

When formed as ribbon bus bar 9400, the bus bars 8524B, 8525B, 8528B,8530B, if exposed, may be covered with an electrically insulative tape.The tape may have a color that matches the color of the backsheet 8502Bso that the bus bars 8524B, 8525B, 8528B, 8530B are not visible to thehuman eye.

Similar to module 8500A, the strings 8504B, 8506B, 8508B, 8510B, 8512Bof the first string set 8525B in module 8500B are connected in parallel,the strings 8514B, 8516B, 8518B, 8520B, 8522B of the second string set8527B in module 8500B are connected in parallel, while the string sets8525B, 8527B themselves are connected in series. FIG. 95 is a close upview of a portion of a back side of the module 8500B with the back sheet8502B removed, illustrating an isolation strip 8532B and associatedelectrical connections configured to be disposed between the two stringsets 8525B, 8527B shown in phantom to electrically connect andstructurally support the string sets 8525B, 8527B. As will beappreciated, the isolation strip 8532B and associated electricalconnections are disposed underneath adjacent strings 8514B, 8516B. In anembodiment, the isolation strip 8532B is a cut portion of the back sheet8502B and disposed between an adhesive layer 8533B and a remainder ofthe back sheet 8502B. The adhesive layer 8533B may be formed fromethylene vinyl acetate (EVA) or another hot melt type of adhesive. Theisolation strip 8532B may be greater in length than the strings. Inanother embodiment, the isolation strip 8532B is sufficiently wide topermit the adjacent strings 8512B, 8514B of the two string sets 8525B,8527B, respectively, to overlap a portion of the isolation strip 8532B.As detailed in FIG. 95, in an embodiment, the isolation strip 8532B isrectangular. One end extends past the strings 8512B, 8514B, in anembodiment so that a portion of each of two of the top bus bars 8523B,8524B is disposed across a portion of its width. The other end iscovered by the strings 8512B, 8514B.

With additional reference to FIG. 96, which is a cross section, explodedview of module 8500B illustrated in FIG. 95 taken along line B-B exceptincluding back sheet 8502B, an electrically conductive ribbon 8538Bextends substantially perpendicularly from top bus bar 8523B behindstring 8512B and about half down the length of the isolation strip andmakes a turn to extend behind string 8514B to connect to bottom bus bar8530B. In this way, a terminal of string 8512B having a polarity may beconnected directly to a terminal of string 8514B having an oppositepolarity. Two additional electrically conductive ribbons 8540B, 8542Bare included to provide connection to junction boxes 8550B, 8551B (FIG.86B), each serving as terminals having opposite polarity. In thisregard, ribbon 8540B extends from top bus bar 8524B and ribbon 8542Bextends from bottom bus bar 8528B so that each conductive ribbon 8540B,8542B serves as hidden interconnects to connect the strings 8525B, 8527Bto a junction boxes 8550B, 8551B. Fix tape (not shown) is included tomaintain the conductive ribbons 8538B, 8540B, 8542B in position on theisolation strip 8532B relative to the strings 8512B, 8514B.

Along other areas of module 8500B away from the electrically conductiveribbon 8538B, for example as shown in FIG. 97, which is a cross section,exploded view of module 8500B illustrated in FIG. 95 taken along lineC-C, the solar module 8500B includes the glass layer 8505, the adhesivelayer 8533B, a top bus bar 8523B at one end of string set 8512B, and abottom bus bar 8530B at an opposite end of string set 8512B, anotheradhesive layer 8533B, and back sheet 8502B.

As shown in FIG. 86B, a back side 8546B of the solar module 8500Bincludes the backsheet 8502B to which two junction boxes 8550B, 8551Bare attached. In an embodiment, the junction boxes 8550B, 8551B do notinclude a bypass diode. In another embodiment, one or both of thejunction boxes 8550B, 8551B includes one or more bypass diodes disposedtherein.

FIG. 85C is a front views of a solar module 8500C in accordance withanother embodiment. Here, the solar module 8500C includes a back sheet8502C and a frame 8503C surrounding all four edges of the back sheet8502C, and includes strings 8504C, 8506C, 8508C, 8510C, 8512C, 8514C,8516C, 8518C, 8520C, 8522C of strips. Module 8500C is formedsubstantially identical manner as module 8500A, except that the stripsincluded in the strings are chamfered. The back view of solar module8500C is identical to that of solar module 8500B.

As alluded to above, the solar module 8500 may incorporate any one ofnumerous electrical configurations. For example, turning to FIG. 89, anelectrical schematic for solar module 8500 is provided, where tenstrings 8900A-8900J are grouped into two sets of strings. The strings ofthe first set of strings 8902A are connected in parallel with each otherand includes a bypass diode 8904A. Similarly, the strings of the secondset of strings 8902B are connected in parallel with each other andincludes a bypass diode 8904B. The two sets of strings 8902A, 8902B areconnected in series with each other.

In another embodiment as illustrated in FIG. 90, an electrical schematicfor solar module 8500 is provided that is identical to the electricalschematic provided in FIG. 89, except no bypass diodes are included.

FIG. 91 is another embodiment of an electrical schematic for solarmodule 8500. Here, each of the ten strings 9100A-9100J are grouped intotwo sets of strings 9102A, 9102B are made up of an upper section 9110A,9110B and a lower section 9112A, 9112B. The upper section 9110A of thefirst set of strings 9102A are arranged in parallel, and the lowersection 9112A of the first set of strings 9102A are arranged inparallel. Each of the sections 9110A, 9112A are further arranged with abypass diode 9114A, 9114B. The upper section 9110B of the second set ofstrings 9102B are arranged in parallel, and the lower section 9112B ofthe first set of strings 9102B are arranged in parallel. Each of thesections 9110B, 9112B are further arranged with a bypass diode 9114C,9114D. The sets of strings 9102A, 9102B are connected in series.

FIG. 92 is a flow diagram of a method 9200 of manufacturing a solarmodule, such as the solar module 8500 described above, if provided. Inan embodiment, a glass plate, serving as a front plate for the solarmodule, is loaded as the substrate at step 9202, then an encapsulationlayer, such as ethylene vinyl acetate (EVA) or poly olefin (POE) film,is laid on top of glass at step 9204. Next, string sets are disposedover the encapsulation layer at step 9206. In an embodiment, a desirednumber of string sets can be appropriately positioned and electricallyconnected by module interconnect busbar to form a desired circuitry. Forexample, the solar module to be manufactured may be made up of 10 setsof strings and hence, may have a length of between about 1600 mm toabout 1700 mm, a width of between about 980 mm to about 1100 mm, and athickness of between about 2 mm to about 60 mm. In another embodiment,the solar module may be made up of 1 to 18 sets of strings and the glassplate can have a length of between about 500 mm to about 2500 mm, awidth of between about 900 mm to about 1200 mm, and a thickness ofbetween about 2 mm to about 60 mm.

In an embodiment, the string sets are positioned over an EVA layer andglass in a configuration as described above with respect to the solarmodule 8500. The string sets may be placed one at a time over the EVAlayer, in an embodiment. Alternatively, the desired number of stringsets may be substantially simultaneously placed over the EVA layer.Suitable machinery for automated laying up of the string sets commonlyused in mass production of solar modules may be employed.

To form connections between the string sets, the strings areinterconnected at step 9208. For example, bus bars are electricallyconnected to corresponding portions of the string sets via conductiveribbon material. An isolation strip including suitably positionedelectrically conductive ribbon adhered thereto, is positioned to extendbetween two adjacent string sets in a manner as described above.Electrical wires to be hidden in a junction box are either protected orotherwise isolated in order to permit the wires to be placed in thejunction box at later stages of manufacture.

Next, another encapsulation layer is laid on top of the string sets atstep 9210. Then, a backsheet is positioned over the encapsulation layerat step 9212 to form one or more lamination stacks. The backsheetmaterial protects the solar module circuitry from environmental impact.In an embodiment, the back sheet is dimensioned slightly larger than theglass plate to improve the manufacturing yield. In another embodiment,the backsheet material can be replaced with glass to offer even betterprotection from environment.

After the back sheet layup, the lamination stacks are loaded into avacuum lamination chamber in which the stacks are adhered to each otherunder a high temperature profile in vacuum. The particular details ofthe lamination process are dependent on the specific properties of theencapsulation material used.

After lamination, the module is framed at step 9214. Framing is employedto provide mechanical strength that is sufficient to withstand wind andsnow conditions after the solar module is installed. In an embodiment,the framing is made up of anodized aluminum material. In anotherembodiment, the framing is disposed on an outer edge of the module. Instill another embodiment, the framing extends over a portion of theglass and/or the back sheet. Additionally, silicone is used to seal thegap between glass and framing so that the edges of the solar module areprotected from unwanted materials that may unintentionally becometrapped within the module which can interfere with the operation of thesolar module.

After framing, a junction box is installed on the backsheet, and theinterconnect ribbon bus bars are soldered or clamped to contact pads inthe junction box at step 9216. Silicone potting material is used to sealthe edge of junction box to prevent moisture and or contaminants gettinginto module. In addition, the junction box itself may be potted toprevent the component from corrosion.

The module is tested at step 9218. Examples of tests include, but arenot limited to flash testing to measure the module power output,electroluminescence testing for crack and micro-crack detection,grounding testing and high pot testing for safety, and the like.

FIG. 93 is a simplified cross-sectional view of a solar module 9300after being processed according to method 9200. As shown, solar module9300 has a glass layer 9302, which serves as a front of the solar module9300, an EVA layer 9304, a ribbon layer 9306, a cell 9308, an isolationstrip 9310, a rear EVA layer 9312, and a back sheet 9314.

While several embodiments of the disclosure have been shown in thedrawings, it is not intended that the disclosure be limited thereto, asit is intended that the disclosure be as broad in scope as the art willallow and that the specification be read likewise. Any combination ofthe above embodiments is also envisioned and is within the scope of theappended claims. Therefore, the above description should not beconstrued as limiting, but merely as exemplifications of particularembodiments. Those skilled in the art will envision other modificationswithin the scope of the claims appended hereto.

What is claimed:
 1. A solar module, comprising: a plurality of stripssingulated from a solar cell, the solar cell including a plurality offront side bus bars and a plurality of back side bus bars, the pluralityof front side bus bars unequally spaced across a front side of the solarcell such that no front side bus bar of the plurality of front side busbars is formed along an edge of a front side of the solar cell, theplurality of back side bus bars including two back side bus bars formedalong a corresponding edge of a back side of the solar cell, wherein allbackside bus bars have a length less than a width of the solar cell; anda plurality of strings formed of the plurality of strips singulated fromthe solar cell, wherein at least two of the plurality of strings areelectrically connected in parallel to form a set.
 2. The solar module ofclaim 1, wherein a remainder of the back side bus bars are unequallyspaced across the back side of the solar cell.
 3. The solar module ofclaim 1, wherein the plurality of strips are disposed in an overlappedarrangement.
 4. The solar module of claim 1, wherein all of the stripshave a substantially equal width.
 5. The solar module of claim 1,wherein all of the strips have a substantially equal area.
 6. The solarmodule of claim 1, wherein each strip of the plurality of stripsincludes a front side bus bar on an edge opposite from an edge on whicha back side bus bar is formed.
 7. The solar module of claim 1, whereinthe plurality of strings includes a first string that has at least 15strips.
 8. The solar module of claim 7, wherein the first stringincludes up to 100 strips.
 9. The solar module of claim 7, wherein atleast some of the at least 15 strips are singulated from different solarcells.
 10. The solar module of claim 1 further comprising at least twosets extending across a width of the solar module and being electricallyconnected in series.
 11. A solar module, comprising: a plurality ofstrips singulated from a solar cell, the solar cell including aplurality of front side bus bars and a plurality of back side bus bars,the plurality of front side bus bars unequally spaced across a frontside of the solar cell such that no front side bus bar of the pluralityof front side bus bars is formed along an edge of a front side of thesolar cell, the plurality of back side bus bars including two back sidebus bars formed along a corresponding edge of a back side of the solarcell, wherein each of at least three front side bus bars of theplurality of front side bus bars have a first width and a second width,the first and second widths being different; and a plurality of stringsformed of the plurality of strips singulated from the solar cell,wherein at least two of the plurality of strings are electricallyconnected in parallel to form a set.
 12. The solar module of claim 11,wherein opposite ends of each of the at least three front side bus barsincludes the first width, and wherein a remaining portion of eachrespective front side bus bar, which extends between the opposite endsof the respective front side bus bar, includes the second width.
 13. Thesolar module of claim 12, wherein the first width is less than thesecond width.
 14. The solar module of claim 13, wherein each front sidebus bar includes a plurality of fingers extending therefrom, and whereinthe first width extends along a length defined by a width of at leastone finger of the plurality of fingers.
 15. The solar module of claim 11further comprising at least two sets extending across a width of thesolar module and being electrically connected in series.
 16. The solarmodule of claim 11, wherein the plurality of strings includes a firststring that has at least 15 strips.
 17. The solar module of claim 11,wherein the first string includes up to 100 strips.
 18. The solar moduleof claim 11, wherein at least some of the at least 15 strips aresingulated from different solar cells.